Doc. MIE10142 Rev.

4 Page 1 of 41

Doc. MIE10142 Rev. 4 Date 12/09/2006

BTS100
THE FAMILY OF MICROPROCESSOR
BATTERY TEST SET
AT CONSTANT CURRENT

(QA.980804)
Doc. MIE10142 Rev. 4 Page 2 of 41

INDEX
1 SAFETY AT WORK ________________________________________________________________ 5

2 GENERAL DESCRIPTION ___________________________________________________________ 6

3 APPLICABLE STANDARDS _________________________________________________________ 6

3.1 Electromagnetic Compatibility ____________________________________________________________ 6

EMISSION _______________________________________________________________________________ 6
IMMUNITY ______________________________________________________________________________ 6

3.2 Low voltage directive ____________________________________________________________________ 7

4 PHYSICAL DESCRIPTION ___________________________________________________________ 8

5 PERFORMANCE SUMMARY _________________________________________________________ 9

6 TECHNICAL CHARACTERISTICS ___________________________________________________ 10

6.1 INTRODUCTION _____________________________________________________________________ 10

6.2 START UP ____________________________________________________________________________ 11

6.3 TEST OF THE BATTERY CHARGER ____________________________________________________ 12

7 EXTERNAL LOAD UNIT ELU/100 ____________________________________________________ 21

7.1 ELU1000 front panel ___________________________________________________________________ 21

7.2 Load connections of ELU/100 ____________________________________________________________ 22

7.3 Configuration: 1 BTS 100 PLUS and 1 ELU/100 ____________________________________________ 24

7.3.1 Best configurations using 1 ELU/100 and 1 BTS 100 PLUS __________________________________ 25
7.3.2 Excel spread-sheet: configuration of 1 BTS-100 with nr 1 ELU-100 ____________________________ 26

7.4 Configuration: 1 BTS 100 PLUS and 2 ELU/100 ____________________________________________ 28

7.4.1 Table for Vnom = 24 V_______________________________________________________________ 29
7.4.2 Table for Vnom = 48 V_______________________________________________________________ 29
7.4.3 Table for Vnom = 110 V______________________________________________________________ 30
7.4.4 Table for Vnom = 220 V______________________________________________________________ 30
7.4.5 Calculation Examples ________________________________________________________________ 31
7.4.6 Excel spread-sheet: configuration of 1 BTS-100 with nr 2 ELU-100 ____________________________ 33

7.5 Using conventional method ______________________________________________________________ 34

8 BTSWA SOFTWARE OPERATING INSTRUCTIONS _____________________________________ 36

8.1 STARTING THE PROGRAM ___________________________________________________________ 36

8.1.1 INSTALLATION ___________________________________________________________________ 36
8.1.2 FILE menu ________________________________________________________________________ 36
8.1.3 VIEW menu _______________________________________________________________________ 36
8.1.4 Test data menu _____________________________________________________________________ 37
8.1.5 Test window _______________________________________________________________________ 37

8.2 TEST MODES ________________________________________________________________________ 38

Doc. MIE10142 Rev. 4 Page 3 of 41

8.2.1 RECORDING MODE _______________________________________________________________ 38

8.2.2 CONTROL MODE __________________________________________________________________ 39
8.2.3 HOW TO SAVE RESULTS AND TEST SETTING. _______________________________________ 39
8.2.4 HOW TO LOAD RESULTS AND TEST SETTING. _______________________________________ 40

9 TEST CURRENT MORE THAN 300 A _________________________________________________ 41

Doc. MIE10142 Rev. 4 Page 4 of 41

Disclaimer
Every effort has been made to make this material complete, accurate, and up-to-date. In addition, changes are periodically added
to the information herein; these changes will be incorporated into new editions of the publication. ISA S.R.L reserves the right to
make improvements and/or changes in the product(s) and/or the program(s) described in this document without notice, and shall
not be responsible for any damages, including but not limited to consequential damages, caused by reliance on the material
presented, including but not limited to typographical errors.
Doc. MIE10142 Rev. 4 Page 5 of 41

1 SAFETY AT WORK

The Product hereafter described is manufactured and tested according to the specifications,
and when used for normal applications and within the normal electrical and mechanical
limits will not cause hazard to health and safety, provided that the standard engineering rules are
observed and that it is used by trained personnel only.

The application guide is published by the Seller to be used together with the Product described in
the corresponding document. The Seller reserves the right to modify the guide without
warning, for any reason. This includes also but not only, the adoption of more advanced
technological solutions and modified manufacturing procedures, and also the addition of other
features, not available in the first release.

The Seller declines any difficulties arising from unknown technical problems. The Seller
declines also any responsibility in case of modification of the Product or of any intervention not
authorized by the Seller in writing.

The warranty includes the repair time and the materials necessary to restore the complete
efficiency of the Product; so, it does not include other burdens, such as the transport and customs
fee. Under no circumstances the warrantee includes any cost that the User may have suffered
because of the Product unavailability and downtime.

The Product is CE marked, and has been tested to operate according to EN 61010-1, with the
following operating conditions:
. Pollution degree 2: normally, non conductive pollution occurs;
. Measurement category 2, for measurement inputs.
Would the Product be used beyond these limits, its safety could be impaired.

At the end of its life, the test set should be disposed in a waste dedicated to electric and electronic
equipment.

The Product deals with voltages and currents that may be lethal to the unadvertised user. Besides,
in order to avoid any danger in case of fault inside the Product, the device under test should have
the following characteristics:
. Connection sockets must be not accessible;
. Input circuits must have an isolation degree at least equal to the one of the Product.

. The symbol
! is related to dangerous output, and is located close to AC and DC
voltage outputs.

. The symbol is located close to the ground socket.

The connection to ground of the device is provided through the mains supply cable; however,
for added safety, the Product should be connected to ground using the dedicated socket.
Doc. MIE10142 Rev. 4 Page 6 of 41

2 GENERAL DESCRIPTION
This technical specification is to describe the technical characteristics, operations and instructions
for a safe start-up of the “BTS100”, designed for the test of battery benches using the discharge
method. This testing device will carry out a constant current discharge to measure the capacity of
new and used battery.

There are two BTS100 models:

1. BTS100 model that doesn’t allow external load connection
2. BTS100 PLUS model that allows external load connection with others ELU/100, up to
N°2 units with max discharging current 300A.

The device is microprocessor based. This allows the control of all the discharging parameters in
real time. It also allows communication with a PC for the control and the data’s representation of
the discharging parameters.

3 APPLICABLE STANDARDS

The test set conform to the EEC directives regarding Electromagnetic Compatibility and Low
Voltage instruments.

3.1 Electromagnetic Compatibility

Directive no. 89/336/CEE dated may 3, 1989, modified by the directive 92/31/CEE dated
may 5, 1992. Applicable Standard : EN61326 + A1 + A2.
EMISSION
- EN 61000-3-3: Limitation of voltage fluctuations and flicker. Acceptable limits: basic.
- CISPR16 (EN 55011 class A): Limits and measurement methods of radio-electric disturbances
for industrial, medical and scientific instruments at radio-electric frequencies.
Acceptable limits for conducted emission:
. 0.15-0.5 MHz: 79 dB pk; 66 dB avg.
. 0.5-5 MHz: 73 dB pk; 60 dB avg.
. 5-30 MHz: 73 dB pk; 60 dB avg.
Acceptable limits for radiated emission:
. 30-230 MHz: 40 dB (30 m)
. 230-1000 MHz: 47 dB (30 m)
IMMUNITY
- EN 61000-4-2: Immunity tests for ESD. Test values: 8 kV in air; 4 kV in contact.
- EN 61000-4-3; Immunity tests for radio frequency interference. Test values (f= 900  5 MHz):
field 10 V/m, modulated AM 80%; 1 kHz
- EN 61000-4-4; Immunity tests for high speed transients (burst). Test values: 2 kV peak; 5/50 ns.
- EN 61000-4-5; Immunity tests for surge. Test values: 1 kV peak differential mode; 2 kV peak
common mode; 1.2/50 us.
- EN 61000-4-6: immunity to low-voltage sinusoidal waveform. Test values: 0.15-80 MHz, 3
Vrms, 80% AM 1 kHz.
- EN 61000-4-8: Immunity tests for low frequency magnetic fields. Test values: 30 Arms/m.
- EN 61000-4-11: Immunity test for power supply drops. Test value: 1 cycle; 100% drop.
Doc. MIE10142 Rev. 4 Page 7 of 41

3.2 Low voltage directive

Directive n. 73/23/CEE, modified by the directive 93/68/CEE.

Applicable standards, for a class I instrument, pollution degree 2, Installation category II: CEI EN
61010-1. In particular:

- Dielectric Rigidity: 1.4 kV, 1 minute.

- Isolation resistance: > 2 MOhm.
- Earth resistance : < 0.1 Ohm.
- Dispersion current: < 5 mA.
- Inputs/outputs protection: IP 4X - IEC 60529.
- Operating temperature: 0 - 50°C; storage: -25°C to 70°C.
- Relative humidity : 5 - 95%, not condensing.
- Vibration: IEC 68-2-6 (20 m/s^2 at 10 – 150 Hz);
- Shock: IEC 68-2-27 (15 g; 11 ms; half-sine).
- Altitude: less than 2000 m.
Doc. MIE10142 Rev. 4 Page 8 of 41

4 PHYSICAL DESCRIPTION
The device (see fig.1) is housed in an aluminium cabinet. The front cover is used to house the
connecting cables, apart of protecting the front panel of the instrument when it is not in use. A rear
cover has also protecting function. Side handles allow easy transportation. The external loads
ELU/100 is housed in identical aluminium cabinets (see fig.2)

Four yellow push buttons are located in the front panel, under the LCD screen (fig 3): they are
used to set the discharging parameters on the LCD. The serial port RS232-C, optoisolated, permits
a link between the device and a remote PC. A large air-grid on the top of front panel allows the
correct ventilation of the load resistors.

The rear panel is dedicated to the electrical connections: battery cables, main power lead,
connections to the external load. They are kept away from the normal operating area which is the
front panel.

The BTS100 PLUS is provides with proper connectors for the external load (see fig.6).

The equipment is complete with power supply cable, battery cables with alligators clips and
RS232 serial cable.

Cable characteristics:
. N. 2 cables, 25 sq. mm cross section, 5 m long. Terminated with a ring terminator on one side,
and with an high current clip on the other side. Clips are red and black.
. N. 1 power supply cord, 2 m long.
. N. 1 serial interface cable, 2 m long.
Doc. MIE10142 Rev. 4 Page 9 of 41

5 PERFORMANCE SUMMARY
The equipment has been manufactured in compliance with an advanced microprocessor
technology to manage the device and perform a dialogue with a remote PC. The RS232 port is an
opto-isolated type in order to have a safe connection to the remote PC; this allows to set, start,
record and print the discharging parameters besides the discharging curves (voltage, current and
amperhour).

MODEL BTS100 BTS100 PLUS

POWER SUPPLY VOLTAGE 230 V AC ± 10% 230 V AC ± 10%
On demand: others On demand: others
FREQUENCY 50-60 Hz 50-60 Hz
POWER FROM THE SUPPLY 100Wmax 100W max
MAX DISCHARGING CURRENT FROM 24Vcc TO 140Vcc 100A 300A
100A plus two external
load EL260V/100
MAX DISCHARGING CURRENT FROM 140Vcc TO 250Vcc 50A 150A
50A plus two external
load EL260V/100
MAX DISCHARGING POWER 14000 W 42000 W
DISCHARGING CURRENT RANGE 999 A 999 A
DISCHARGING CURRENT RESOLUTION 1A 1A
DISCHARGING CURRENT ACCURACY +/- 1% +/- 1%
BATTERY VOLTAGE MEASURE RANGE 500 V 500 V
BATTERY VOLTAGE MEASURE RESOLUTION 0.1 V 0.1 V
BATTERY VOLTAGE MEASURE ACCURACY +/- 1% +/- 1 V +/- 1% +/- 1 V
AUTOMATIC STOP TIME LIMIT 9h:59m 9h:59m
OPERATING AMBIENT TEMPERATURE 0° - 40°C 0° - 40°C
TERMAL PROTECTION YES YES
REVERSED BATTERY INSERTION PROTECTION YES YES
OVER VOLTAGE BATTERY PROTECTION YES YES
DISCHARGER CABINET DIMENSIONS L34.5XD60.8XH5 L34.5XD60.8XH5
2.5 2.5
EXTERNAL LOAD CABINET DIMENSION L34.5XD60.8XH5 L34.5XD60.8XH5
2.5 2.5
DISCHARGER WEIGHT 30 Kg 30 Kg
EXTERNAL LOAD WEIGHT 30 Kg 30 Kg
SERIAL CABLE 9 way; 2 to 2; 3 9 way; 2 to 2; 3
to 3; 5 to 5 to 3; 5 to 5
Doc. MIE10142 Rev. 4 Page 10 of 41

6 TECHNICAL CHARACTERISTICS
6.1 INTRODUCTION

All instruments are equipped with a backlighted alphanumeric display located in the front panel.
The following parameters will be shown during the discharge:
 Voltage of battery;
 Minimum battery voltage: this is the minimum battery value and causes the test stop when
reached during the discharge. At the start-up, this value is automatically set to 70% of the
battery voltage. You can adjust this value as you wish by means of the + / - push-buttons in
steps of 0.1V. This value can be also set via PC.
 Discharge current; adjustable from 1 to 100A (BTS alone; 110 V) or 50 A (BTS alone; 220
V), in steps of 1A. If the external load is connected, current limit is 300 A both at 110 V and
220 V. If one BTS plus two ELU units are used, maximum current to be programmed is 300 A
for 110 V operation, and 150 A for 220 V operation. The absolute limit of 300 A at 220 V
operation is for the case of further loads, besides the two ELU units.
 Elapsed time from the start of the test; when the programmed maximum time for the
discharge has been reached, this causes the test stop.
 Discharged Amp/h: the ampere-hours meter measures the discharged Amps/h from the start of
the test. The value can only be reset by switching the unit off or by disconnecting the battery.

In case of errors, the same display shows the relative message:

MESSAGE ON DISPLAY CAUSES OF MESSAGE INTERVENTION

CONNECT BATTERY
INVERTED BATTERY
BATTERY VOLTAGE OVER
LIMITS
OVERTEMPERATURE – WAIT
CURRENT ALARM - SWITCH
OFF
CURRENT ALARM MODULE 0
SWITCH OFF
CURRENT ALARM MODULE 1
SWITCH OFF
CONTROL ALARM - SWITCH
OFF
LOW CURRENT - SWITCH
OFF
HIGH CURRENT - SWITCH
OFF
No connection with battery terminals Connect the battery to the
discharger
The battery has been connected with reversed Connect the battery properly
polarity
You have connected battery with a voltage Connect a battery with proper
higher than 260V. The connected battery voltage.
cannot undergo the discharge test
The internal thermal protection has tripped due Switch the discharger off and
to excessive heat. check the correct operation of
fans and the free circulation
of air
Unexpected overcurrent current on the Check battery connection
electronic section during normal operation
Unexpected over current on the internal load Check battery connection
section during normal operation
Unexpected overcurrent from the external load Check battery connection
section during normal operation
Impossible to discharge the current value set or Check current values set
failure on resistors bank
This actually means that the current in the EXT Set a new value or change
LOAD is higher than the set value the EXT LOAD
configuration
This actually means that the current in the EXT Set a new value or change
LOAD is too low and that the main unit is the EXT LOAD
called to discharge more than its own configuration
maximum value (50 or 100 A depending on the
battery voltage)
Doc. MIE10142 Rev. 4 Page 11 of 41

6.2 START UP

For a correct start up of the discharger, follow these instructions:

 For safety reasons we recommend that you place the BTS and the possible external loads (if in
use) away from the battery room. Also, in order to prevent overheating of the device, the two
ventilation grids must be kept clear.
 Connect the BTS100 to the main power supply.
 Connect the discharger to the external loads by means of the relative power leads (see fig.7,8)
 Connect the BTS100 to the battery to be tested.;
 If you are using BTS100 PLUS model, press the green button “insert ext.load” located in the
rear (see fig.6).
 Switch on the unit by means of
the mains circuit breaker located
in the rear panel; the displayed
readings are similar to the ones
displayed in the figure.

 Select the parameter to adjust by

pressing the button SET; the
relative parameter will start
blinking
 Adjust the blink value pressing buttons + and - .
 Start the test by pressing the
START/STOP button, which is
also used to stop the discharge;
note that you can start and stop the
discharge as many times as you
wish.

The discharge will also interrupted in

case of:
 The minimum battery voltage Vmin has been reached
 The maximum time for the test has elapsed.
 Thermal protection trip. This intervention will be shown on the display with reading
OVERTEMPERATURE BLOCK.

Once a discharge is over and you want to proceed with another discharge test, you have to switch
off the device in order to reset the test parameters.
The serial interface RS232 located in the panel allows to control the instrument with a PC and the
software BTSWA. Here you can set all discharge parameters and produce a record like the one
displayed here below.
Doc. MIE10142 Rev. 4 Page 12 of 41

6.3 TEST OF THE BATTERY CHARGER

The above applies only to the test of batteries.

Sometimes, it is necessary to test the battery charger, with a constant current load. It is necessary
to be careful, because the battery charger includes a maximum current protection that, if it
intervenes, causes sudden variations of voltage output. This behaviour can cause the fault of BTS:
take care to operate at a current less than the threshold!

If the battery charger threshold is to be tested, it is possible to use one or more ELU100, that don’t
suffer because of these variations.
Doc. MIE10142 Rev. 4 Page 13 of 41

Aluminium cabinet for BTS and ELU100 - Figure 1

Anterior and backside ELU100 - Figure 2

Doc. MIE10142 Rev. 4 Page 14 of 41

BTS100 - Figure 3
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BTS100 connections - Figure 4

Doc. MIE10142 Rev. 4 Page 16 of 41
Doc. MIE10142 Rev. 4 Page 17 of 41

Battery connections for BTS100 and BTS100PLUS - Figure 5

Doc. MIE10142 Rev. 4 Page 18 of 41

BTS100PLUS - Figure 6
Doc. MIE10142 Rev. 4 Page 19 of 41

BTS100PLUS connections - Figure 7

Doc. MIE10142 Rev. 4 Page 20 of 41

ELU100 connections - Figure 8

Doc. MIE10142 Rev. 4 Page 21 of 41

7 EXTERNAL LOAD UNIT ELU/100

BTS100 PLUS together with 1 or 2 external loads ELU100 allows increasing the discharging
current. Here is the max discharging current provided by any device alone:

Model 0-140V 140-250V

BTS100 0-100A 0-50A
BTS100 PLUS 0-100A 0-50A
ELU100 0-100A 0-50A

A BTS with 2 external loads can discharge up to 300 A at Vmax = 140V, and 150 A at 140-150V.

Configurations 0-140V 140-250V

BTS100 PLUS 0-100A 0-50A
BTS100 PLUS + 1 ELU100 0-200A 0-100A
BTS100 PLUS + 2 ELU100 0-300A 0-150A

NOTE: at 220 V, the BTS plus external load accepts a maximum discharging current of 300 A.
This can be achieved connecting further loads, up to 150 A, in parallel to BTS and the two ELU.
However, BTS and ELU cannot exceed 50 A each; besides, BTS can control only up to 50 A.

On following we suggest some illustrative charts concerning the range of discharging current
according to the configurations made on the unity ELU100.

7.1 ELU1000 front panel

All resistance terminations are available at the front panel. This is the way they are connected:

1 4 6

0.45 

0.9 
1.8 
3

0.45 
1.8 

2 5

Every resistor can discharge not more than 68 A.

Doc. MIE10142 Rev. 4 Page 22 of 41

7.2 Load connections of ELU/100

Configuration Nr 1 Configuration Nr 2 Configuration Nr 3

1 4 6 1 4 6 1 4 6

3 3 3

5 5 5
2 2 2

Configuration Nr 4 Configuration Nr 5 Configuration Nr 6

1 4 6 1 4 6 1 4 6

3 3 3

2 5 2 5 2 5
2 2 2

Configuration Nr 7 Configuration Nr 8 Configuration Nr 9

1 4 6 1 4 6 1 4 6

3 3 3

5 5 55
2 2

Configuration Nr 10 Configuration Nr 11 Configuration Nr 12

1 4 6 1 4 6 1 4 6

3 3 3

5 2 5 5
2 2 2

Configuration Nr 13 Configuration Nr 14 Configuration Nr 15

1 4 6 1 4 6 1 4 6
3
3 3

5 5 5
2 2 2
Configuration Nr 16 Configuration Nr 17 Configuration Nr 18
1 4 6 1 4 6 1 4 6

3 3
3
5 2 5 2 5
2 2
Doc. MIE10142 Rev. 4 Page 23 of 41
Configuration Nr 19
1 4 6

2 5

The corresponding resistance values, as well as the maximum current and the maximum voltage,
are resumed in the following table:
Nr R [ ] Imax [ A ] Vmax [ V ]
1 5.4 68 367
2 4.5 68 306
3 3.6 68 244
4 3.15 68 214
5 2.7 68 184
6 1.8 68 122
7 1.53 68 104
8 1.35 136 184
9 1.125 136 153
10 0.9 136 122
11 0.818 125 102
12 0.6 204 122
13 0.45 136 61
14 0.36 170 61
15 0.3 204 61
16 0.225 136 30
17 0.18 170 30
18 0.164 186 30
19 0.15 204 30

The external laod allows the discharge of currents higher than 100 A.
Doc. MIE10142 Rev. 4 Page 24 of 41

7.3 Configuration: 1 BTS 100 PLUS and 1 ELU/100

In order to determine the best configuration of the external laod, the user must know some
parameters:
- Nominal voltage of the battery (that would also be the starting voltage) Vmax
- The minimum battery voltage Vmin
- The discharging current
The problem is that, while the battery voltage decreases, also the current through ELU decreases:
BTS must increase its discharging current, so that the total is constant. During the test, it must be
verified that the current through ELU never reaches zero, and that the current through BTS never
exceeds 100 or 50 A. The procedure to get the right configuration is the following:
- IBTS (max) = 100 A
- IELU (min) = Imax - 100 A
- RELU (max) = Vmin / IELU (min)
- Select one configuration for which RELU < RELU (max)
- IELU (max) = Vmax / RELU
- Verify that the maximum current on the ELU is lower than the allowed current.
Let’s give an example:
- Vmax = 115 V
- Vmin = 84 V
- Imax = 180 A
- IELU (min) = Imax - 100 A = 180-100 = 80A
- RELU (max) = Vmin / IELU (min) = 84 / 80 = 1.05 
- Select configuration for which RELU < RELU (max) : NR 10  RELU = 0.9  < 1.05
- IELU (max) = Vmax / RELU = 115 / 0.9 = 128 A < 136 A
- Verify that the maximum current on the ELU is lower than the allowed current: YES.
Just to remind you, the configuration NR 10 is the following:

Configuration Nr 10: 0.9  - 136 A

max
1 4 6

5
2
Doc. MIE10142 Rev. 4 Page 25 of 41

7.3.1 Best configurations using 1 ELU/100 and 1 BTS 100 PLUS

The best configuration is always a compromise and depends on the user. By the way some simple
rules must be respected in order not to overheat the instrument, or even damage it.

Type Ni-Cd Lead Ni-Cd Lead Ni-Cd Lead Ni-Cd Lead

Vmax 24.7 25.2 49.4 48.3 111.8 111.3 223.6 222.6
Vmin 19 21.6 38 41.4 86 95.4 172 190.8
I (A) Configurations:
BTS100 + 1 ELU 100
51 BTS alone BTS alone BTS alone BTS alone BTS alone BTS alone 12 12
75 BTS alone BTS alone BTS alone BTS alone BTS alone BTS alone 13 13
95 BTS alone BTS alone BTS alone BTS alone BTS alone BTS alone 3 3
115 9  16 8  16 6  13 5  13 19 19 NO NO
130 12  16 12  16 9  13 8  13 5  10 4  10 NO NO
145 14  17 13  18 11  14 10  14 6  10 8  10 NO NO
160 15  18 15  18 12  15 12  14 8  10 8  10 NO NO
185 17  19 16  19 14  15 13  15 10 10 NO NO
205 17  19 17  19 14  15 14  15 12 11 or 12 NO NO

This table helps you choose the best ELU 100 configuration for your battery level.
Example: if you have for instance:
 Vnom: 48V
 Type: Ni-Cd
 Current: 130 A
The suitable configurations are 9, 10, 11, 12 and 13.
The corresponding resistance values, on the LSU, are: 1.125 – 0.9 – 0.818 – 0.6 – 0.45
A configuration in the middle is to be preferred, the NR 11 or 12 are good options, for which
we have the following currents flowing into the devices:

Configuration nr 11:
Min Max
ELU 46.5 60.4
BTS 69.6 83.5

Configuration nr 12:
Min Max
ELU 63.3 82.3
BTS 47.7 66.7
Doc. MIE10142 Rev. 4 Page 26 of 41

Doc. MIE10142 Rev. 4 Page 26 of 41

7.3.2 Excel spread-sheet: configuration of 1 BTS-100 with nr 1 ELU-100
Other combinations can be obtained for other Battery voltage ranges. If you are looking at this manual on your PC, then look at the following table:
Nr R [ ] Imax [ A ] Vmax [ V ] Battery Data ELU configur. 11
1 5,400 68 367 Current 130,0 R [ W] 0,818
2 4,500 68 306 Vmax 49,4 Rated I 125
3 3,600 68 244 Vmin 38,0 Vmax 102
4 3,150 68 214
5 2,700 68 184 BTS rated I 100
6 1,800 68 122 Currents in the devices
7 1,530 68 104 Min Max
8 1,350 136 184 ELU 46,5 60,4
9 1,125 136 153 BTS 69,6 83,5
10 0,900 136 122
11 0,818 125 102
CORRECT
12 0,600 204 122

13 0,450 136 61
14 0,360 170 61 Please contact ISA Srl to get the document BTS100.doc
15 0,300 204 61
16 0,225 136 30
17 0,180 170 30
18 0,164 186 30
19 0,150 204 30

(QA.980804)
Doc. MIE10142 Rev. 4 Page 27 of 41

Doc. MIE10142 Rev. 4 Page 276 of 41

 Enter into the table by double clicking in it (it is an Excel spread-sheet)
 Set the maximum current you want to discharge;
 Set the minimum and maximum voltage according to the type and number of battery cell;
 Choose the configuration for ELU.
 The spread-sheet automatically:
1. Computes the maximum current that can be discharged by the BTS; it depends on the
battery voltage:
 Vbatt > 146  BTS I max = 50 A
 Vbatt  146  BTS I max = 100 A
2. Retrieves R, Imax and Vmax from the table on the left hand side
3. Calculates all currents at both Vmax and Vmin (discharge start and stop)
4. Verifies that none of the values exceeds the maximum current values for BTS and ELUs.
5. The result is automatically given by the words:
 CORRECT
 WRONG

(QA.980804)
Doc. MIE10142 Rev. 4 Page 28 of 41

7.4 Configuration: 1 BTS 100 PLUS and 2 ELU/100

The following table resumes all resistance values that can be obtained by the parallel of two
ELU100. In case you need a special resistance value, you can find out the closest value to yours
on this table, then look at the number of column and row to define the proper configuration.
ELU 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
ELU 2 5.400 4.500 3.600 3.150 2.700 1.800 1.530 1.350 1.125 0.900 0.818 0.600 0.450 0.360 0.300 0.225 0.180 0.164 0.150
1 5.400 2.700 2.455 2.160 1.989 1.800 1.350 1.192 1.080 0.931 0.771 0.710 0.540 0.415 0.338 0.284 0.216 0.174 0.159 0.146
2 4.500 2.455 2.250 2.000 1.853 1.688 1.286 1.142 1.038 0.900 0.750 0.692 0.529 0.409 0.333 0.281 0.214 0.173 0.158 0.145
3 3.600 2.160 2.000 1.800 1.680 1.543 1.200 1.074 0.982 0.857 0.720 0.667 0.514 0.400 0.327 0.277 0.212 0.171 0.157 0.144
4 3.150 1.989 1.853 1.680 1.575 1.454 1.145 1.030 0.945 0.829 0.700 0.649 0.504 0.394 0.323 0.274 0.210 0.170 0.156 0.143
5 2.700 1.800 1.688 1.543 1.454 1.350 1.080 0.977 0.900 0.794 0.675 0.628 0.491 0.386 0.318 0.270 0.208 0.169 0.155 0.142
6 1.800 1.350 1.286 1.200 1.145 1.080 0.900 0.827 0.771 0.692 0.600 0.562 0.450 0.360 0.300 0.257 0.200 0.164 0.150 0.138
7 1.530 1.192 1.142 1.074 1.030 0.977 0.827 0.765 0.717 0.648 0.567 0.533 0.431 0.348 0.291 0.251 0.196 0.161 0.148 0.137
8 1.350 1.080 1.038 0.982 0.945 0.900 0.771 0.717 0.675 0.614 0.540 0.509 0.415 0.338 0.284 0.245 0.193 0.159 0.146 0.135
9 1.125 0.931 0.900 0.857 0.829 0.794 0.692 0.648 0.614 0.563 0.500 0.474 0.391 0.321 0.273 0.237 0.188 0.155 0.143 0.132
10 0.900 0.771 0.750 0.720 0.700 0.675 0.600 0.567 0.540 0.500 0.450 0.429 0.360 0.300 0.257 0.225 0.180 0.150 0.139 0.129
11 0.818 0.710 0.692 0.667 0.649 0.628 0.562 0.533 0.509 0.474 0.429 0.409 0.346 0.290 0.250 0.219 0.176 0.148 0.137 0.127
12 0.600 0.540 0.529 0.514 0.504 0.491 0.450 0.431 0.415 0.391 0.360 0.346 0.300 0.257 0.225 0.200 0.164 0.138 0.129 0.120
13 0.450 0.415 0.409 0.400 0.394 0.386 0.360 0.348 0.338 0.321 0.300 0.290 0.257 0.225 0.200 0.180 0.150 0.129 0.120 0.113
14 0.360 0.284 0.333 0.327 0.323 0.318 0.300 0.291 0.284 0.273 0.257 0.250 0.225 0.200 0.180 0.164 0.138 0.120 0.113 0.106
15 0.300 0.216 0.281 0.277 0.274 0.270 0.257 0.251 0.245 0.237 0.225 0.219 0.200 0.180 0.164 0.150 0.129 0.113 0.106 0.100
16 0.225 0.174 0.214 0.212 0.210 0.208 0.200 0.196 0.193 0.188 0.180 0.176 0.164 0.150 0.138 0.129 0.113 0.100 0.095 0.090
17 0.180 0.159 0.173 0.171 0.170 0.169 0.164 0.161 0.159 0.155 0.150 0.148 0.138 0.129 0.120 0.113 0.100 0.090 0.086 0.082
18 0.164 0.146 0.158 0.157 0.156 0.155 0.150 0.148 0.146 0.143 0.139 0.137 0.129 0.120 0.113 0.106 0.095 0.086 0.082 0.078
19 0.150 0.146 0.145 0.144 0.143 0.142 0.138 0.137 0.135 0.132 0.129 0.127 0.120 0.113 0.106 0.100 0.090 0.082 0.078 0.075

For instance, if we need the value R=0.370, this value is between configuration 13-5 (0.386)
and 13-6 (0.360), so we can choose the 13-6, which is closer to 0.370.

(QA.980804)
Doc. MIE10142 Rev. 4 Page 29 of 41

The following tables intend to give an example of the best configuration for Ni-Cd and Lead
batteries.
7.4.1 Table for Vnom = 24 V

Configurations: BTS100 + 2 ELU100

Battery type

Ni-Cd: 20 elements Lead : 12 elements

Vmax 1.3 x 20 = 24.7 Vmax 25.2
Vmin 1.05 x 20 = 21.0 Vmin 21.6
I (A) ELU 100 NR 1 ELU 100 NR 2 ELU 100 NR 1 ELU 100 NR 2
210 15 15 14 15
220 15 16 15 15
240 16 16 15 16
260 16 16 16 16
280 16 17 16 17
300 17 17 17 17

7.4.2 Table for Vnom = 48 V

Configurations: BTS100 + 2 ELU100

Battery type

Ni-Cd: 40 elements Lead : 24 elements

Vmax 1.3 x 40 = 52 Vmax 24 x 2.1 = 50.4
Vmin 1.05 x 40 = 42 Vmin 24 x 1.8 = 43.2
I (A) ELU 100 NR 1 ELU 100 NR 2 ELU 100 NR 1 ELU 100 NR 2
210 12 12 12 12
220 12 12 12 12
240 12 13 12 13
260 13 13 13 13
280 13 14 13 14
300 14 14 14 14
Doc. MIE10142 Rev. 4 Page 30 of 41

7.4.3 Table for Vnom = 110 V

Configurations: BTS100 + 2 ELU100

Battery type

Ni-Cd: 92 elements Lead: 56 elements

Vmax 92 x 1.3 = 119.6 Vmax 56 x 2.1 = 117.6
Vmin 92 x 1.05 = 96.6 Vmin 56 x 1.8 = 100.8
I (A) ELU 100 NR 1 ELU 100 NR 2 ELU 100 NR 1 ELU 100 NR 2
210 8 8 8 8
220 8 8 8 8
240 8 9 8 9
260 9 9 9 9
280 9 10 9 10
300 10 10 10 10

7.4.4 Table for Vnom = 220 V

Configurations: BTS100 + 2 ELU100

Battery type

Ni-Cd: 180 elements Lead: 112 elements

Vmax 180 x 1.3 = 234 Vmax 112 x 2.1 = 235
Vmin 180 x 1.05 = 189 222.6 112 x 1.8 = 202
I (A) ELU 100 NR 1 ELU 100 NR 2 ELU 100 NR 1 ELU 100 NR 2
110 1 1 1 1
120 1 2 1 2
130 2 2 2 2
140 2 3 2 3
150 3 3 3 3
Doc. MIE10142 Rev. 4 Page 31 of 41

7.4.5 Calculation Examples

Other configurations are possible. But since the number of combination is so high, it is impossible
to list all possible cases for different voltage values, so we’ll describe some special case. However
a procedure to find out the right configuration for both ELU will be given.
Voltage group: 24V
Battery type: Ni-Cd
Number of elements: 19 elements
Discharge current: 300 A
Min voltage: 1.00 x N°elements = 19V
Max voltage: 1.3V x N°elements = 24.7V

RESISTANCE VALUES
ELU Nr 1 ELU Nr 2 Total BTS
Current = 300.0 0.180 0.164 0.086
CURRENTS
Vmax = 24.7 137.2 150.6 287.8 12.2
Vmin = 19.0 105.6 115.9 221.4 78.6

WARNING: The total resistance is so low that it could be comparable with the resistance
contact of all wirings. So we advise to use the configuration NR 19, 0,15, for one of the two
ELU, even thought the minimum calculated current for the BTS is lower than zero.

Voltage group: 48V

Battery type: Ni-Cd
Number of elements: 38 elements
Discharge current: 300 A
Min voltage: 1.00 x N°elements = 38V
Max voltage: 1.3V x N°elements = 49V

RESISTANCE VALUES
ELU Nr 1 ELU Nr 2 Total BTS
Current = 300 0.450 0.300 0.180
CURRENTS
Vmax = 49 108.9 163.3 272.2 27.8
Vmin = 38 84.4 126.7 211.1 88.9
Doc. MIE10142 Rev. 4 Page 32 of 41

Voltage group: 110V

Battery type: Ni-Cd
Number of elements: 86 elements
Discharge current: 300 A
Min voltage: 1.00 x N°elements = 86V
Max voltage: 1.3V x N°elements = 112 V

RESISTANCE VALUES
ELU Nr 1 ELU Nr 2 Total BTS
Current = 300 0.900 0.818 0.429
CURRENTS
Vmax = 112 124.4 136.9 261.4 38.6
Vmin = 86 95.6 105.1 200.7 99.3

Voltage group: 220V

Battery type: Ni-Cd
Number of elements: 180
Discharge current: 150 A
Min voltage: 1.00 x N°elements = 180 V
Max voltage: 1.3V x N°elements = 234 V

RESISTANCE VALUES
ELU Nr 1 ELU Nr 2 Total BTS
Current = 150.0 3.600 3.150 1.680
CURRENTS [ A ]
Vmax = 234.0 65.0 74.3 139.3 10.7
Vmin = 180.0 50.0 57.1 107.1 42.9
Doc. MIE10142 Rev. 4 Page 33 of 41

7.4.6 Excel spread-sheet: configuration of 1 BTS-100 with nr 2 ELU-100

Other combinations can be obtained for other Battery voltage ranges. If you are looking at this manual on your PC, then look at the following table:
Nr R [ ] Imax [ A ] Vmax [ V ] ELU #1 ELU #2
1 5,400 68 367 Battery Data Configur. 1 Configur. 2
2 4,500 68 306 Current 120,0 R [ ] 5,400 R [ ] 4,500
3 3,600 68 244 Vmax 235,0 Rated I 68 Rated I 68
4 3,150 68 214 Vmin 202,0 Vmax 367 Vmax 306
5 2,700 68 184
6 1,800 68 122 BTS Max I 50
7 1,530 68 104
8 1,350 136 184 Currents in the devices
9 1,125 136 153 At Vmax At Vmin
10 0,900 136 122 ELU 1 43,5 37,4
11 0,818 125 102 ELU 2 52,2 44,9
12 0,600 204 122 BTS 24,3 37,7
13 0,450 136 61
14 0,360 170 61
CORRECT
15 0,300 204 61

16 0,225 136 30 Please contact ISA to receive the document BTS100.doc

17 0,180 170 30
18 0,164 186 30
19 0,150 204 30

(QA.980804)
Doc. MIE10142 Rev. 4 Page 34 of 41

 Enter into the table by double clicking in it (it is an Excel spread-sheet);

 Set the maximum current you want to discharge;
 Set the minimum and maximum voltage according to the type and number of battery cell;
 Choose the configuration for ELU #1 and ELU #2.
The spread-sheet automatically:
6. Compute the maximum current that can be discharged by the BTS; it depends on the
battery voltage:
 Vbatt > 146  BTS I max = 50 A
 Vbatt  146  BTS I max = 100 A
7. Retrieves R, Imax and Vmax from the table on the left hand side;
8. Calculates all currents at both Vmax and Vmin (discharge start and stop);
9. Verifies that none of the values exceeds the maximum current values for BTS and ELUs.
10. the result is automatically given by the words:
 CORRECT
 WRONG
If you are not able to keep the current within the range, then you have either to change resistance
configuration or reduce the discharging current.

In case you’re not reading this manual on your PC, so that you cannot double click on the table,
than use the following method.

7.5 Using conventional method

1. You must know the element’s number

2. You must know the discharging current
3. Establish the voltage group: 24V, 48V, 72V, 110V, 220V
4. You must know the type of battery: Lead or Ni-Cd
5. Calculate Vmax and Vmin:
 Lead case: Vmax = 2.1V x elements numb.
Vmin = 1.8V x elements numb.
 Ni-Cd case: Vmax = 1.3V x elements numb.
Vmin = 1.05V x elements numb.
6. Choose a configuration in the appropriate voltage group so that the Vmin-Vmax range stays
inside the voltage range.
7. Calculate current range as following:
Vbatt < 140V and I discar <=200 A
 Imin = Ielu + Ibts = (Vmax / config.resist.) + 2
 Imax = Ielu + Ibts = (Vmin / config.resist.) + 100
Vbatt < 140V and Idiscar >200 A
 Imin = Ielu + Ielu + Ibts = (Vmax / config.resist.) + (Vmax / config.resist.) + 2

(QA.980804)
Doc. MIE10142 Rev. 4 Page 35 of 41

 Imax = Ielu + Ielu + Ibts = (Vmin / config.resist.) + (Vmin / config.resist.) + 100

Vbatt > 140V and Idiscar <=100 A
 Imin = Ielu + Ibts = (Vmax / config.resist.) + 2
 Imax = Ielu + Ibts = (Vmin / config.resist.) + 50
Vbatt > 140V and I discar >100 A
 Imin = Ielu + Ielu + Ibts = (Vmax / config.resist.) + (Vmax / config.resist.) + 2
 Imax = Ielu + Ielu + Ibts = (Vmin / config.resist.) + (Vmin / config.resist.) + 50
8. See if the desired discharging current stays inside the calculated interval:
 If YES and the ELU100’s current is lower than the max current of the chosen
configuration then you can start the test; END OF PROCEDURE.
 If NO, choose a configuration with an higher resistance and restart from point 7

NOTE: in case you can’t find the right configuration, just try to decrease discharging current and
repeat the calculation.
Doc. MIE10142 Rev. 4 Page 36 of 41

8 BTSWA SOFTWARE OPERATING INSTRUCTIONS

The program BTSWA runs with Windows 95 or later versions.
The functions of the program are the followings:
- To configure BTS;
- To start and stop the battery discharge;
- To import data of the test underway;
- To display the BTS set-up;
- To display the discharge diagram;
- To save test results;
- To display former test results;
- To print test results.

8.1 STARTING THE PROGRAM

8.1.1 INSTALLATION
In order to install the BTSWA program, execute the setup program BTSWA20EN.EXE
This will start the installation program, create the appropriate folders on the local computer and
create the relative icons to be used to start the program.
Once installed, BTSWA can run double clicking on the new icon.

8.1.2 FILE menu

. Open: For opening and display test results already saved
. Save: For saving a test results and test data
. New : For stating a new test
. Pint Graph: For printing the selected graphic
.Print table: For the complete print of a selecedt test results. This print command will send to the
printer all the measures recorded every 10 seconds.
. Print resume: For the printing of a test underway. This print command will send to the printer all
the measure recorded every 10 minutes.
. Config printer : For printer configuration.
. Exit: To exit BTSWA program.
8.1.3 VIEW menu
It opens the following configuration window that displays the test setting.

The configuration of the test can be saved in order to be used for further tests.
Doc. MIE10142 Rev. 4 Page 37 of 41

8.1.4 Test data menu

It opens the following window, where test data can be input.

8.1.5 Test window

. On the screen it will show the discharging graphic of the current test and the current parameters:
. Elapsed time, Battery voltage (blue line), Current dischrged, Amperhour discharged (green line),
Vstop ( Minimum Voltage Threshold).
In order to measure a particular point on the discharging curve move the cursor with the mouse to
the desired position and click with the mouse. The program will show all the parameters in the
measuring box.
Doc. MIE10142 Rev. 4 Page 38 of 41

8.2 TEST MODES

The test program BTSWA can be used in two different modes:

. Recoding mode
. Control mode

8.2.1 RECORDING MODE

It can be used just to record and save the discharging results and the test data.
. Connect the battery to the BTS/100;
. Switch on the BTS/100;
. Open the BTSWA program;
. Connect the BTS serial port to the PC
. Set the test parameter on BTS front panel and start the discharge.
. The display window will show the message: DISCHARGING, that is the status of the BTS, and
will allow watching the test execution. This windows will display all the changing status of the
BTS:
. WAITING CONNECTION: When the PC is not connected to the BTS
. WRONG POLARITY: when the connection to the battery is wrong
Doc. MIE10142 Rev. 4 Page 39 of 41

. DISCHARGE SUSPENDED. When the discharge test has been stop by the BTS unit.
. Other ERROR MESSAGES: please refer to the BTS manual fo eror messages.
NOTE: the STOP button is not active when the BTSWA is in Recording mode.

8.2.2 CONTROL MODE

It allows to control the discharging test directly from PC. It is important to run the program first
before to switch on the BTS. If the BTS is switch on before it will take automatically the control
of the test. If this happens it is necessary to switch off the BTS and switch on after the PC has
been connected and the program has been loaded.
.Connect the battery to the BTS/100;
. Switch on the PC and open the program BTSWA;
. Connect the BTS serial port to the PC;
. Switch on the BTS/100.
At the bottom of the screen, the SET UP is active now and it is necessary to fill in the testing
parameters:
. CURENT DISCHARGED
. BATTERY VOLTAGE
. MINIMUM BATTERY VOLTAGE THRESHOLD
. MAX TIME
Once the parameter has been entered press START. The command OPEN allows to load a saved
setting to be used again for a new test.
The status line will show EDITING and then DISCHARGING while the test starts.
The status windows will display all the changing status of the BTS:
. WAITING CONNECTION: When the PC is not connected to the BTS
. WRONG POLARITY: when the connection to the battery is wrong
. DISCHARGE SUSPENDED. When the discharge test has been stop.
And error messages.
STOP: This button is active and allows to stop the test from PC when the BTSWA is in Control
mode.
8.2.3 HOW TO SAVE RESULTS AND TEST SETTING.

It is possible to save results and setting configurations.

Opening FILE the command SAVE, will save all the result of test: graphic, all the measures and
the test data (Location, operator, date and time of the test). The extension of this file is .bts
Opening VIEW it is possible to save the setting parameter of the test. The extension of this file is
.cmd.
Doc. MIE10142 Rev. 4 Page 40 of 41

8.2.4 HOW TO LOAD RESULTS AND TEST SETTING.

To load a result, press FILE, OPEN and select the .bts file. Several graphic results can be opened
together for comparisons.
To load a setting, first follow instructions to enter in control mode. Then, press SET UP on the
command line at the bottom of the screen, and click on OPEN. Select a saved setting and if correct
press START to send the instruction to the BTS. The BTS will start a discharging test according to
the loaded settings.
Doc. MIE10142 Rev. 4 Page 41 of 41

9 TEST CURRENT MORE THAN 300 A

If sometimes it is mandatory to discharge at a current higher than 300 a (or higher than 150 A at
220 V), it is possible to do it using more than a BTS (plus ELU) in parallel.

The following figure refers to a case where you own: one BTS100 plus, and an ELU, and also two
BTS100.

If your discharging current is, for instance, 340 A at 110 V, you can:
. Program 160 A for ELU + BTS100 plus;
. Program 90 A each on the two BTS100.

When you start the test, the total discharging current is 340 A, as desired. The three BTS will be
programmed with the same minimum voltage and maximum time; the test start error can be made
less than 1 s, at no detriment to test result accuracy.

You can get the same result using two BTS100plus and two ELU, or one BTS100plus, with two
ELU, and one BTS100.