Specification Provision of tested NGSS 1. The Contractor shall provide preconfigured Li-Ion battery packs as per the following specifications: 1.1 The Contractor shall supply preconfigured SAFT 2S1P 176065 STS Li-Ion battery pack, 7.5V, 6.8 Ah, 51 Wh (composed of two each SAFT MP176065 cells in Option G3 aluminium housing); 1.2 Battery connection shall be provided through 15 cm long isolated wires (AWG20) fitted to one FCI Dubox 65240-002 female connector, using FCI Dubox 76357-301 Crimp-to-Wire Contact Inserts; and 1.3 The connection wires shall be color coded as follows: Black color for the negative battery pack pole and Red color for the positive battery pack pole (Figure 1). Figure 1 - Completely configured 2s1p INT 176065 STS battery pack and FCI Dubox 65240-002 connector Page 1 of 6
2. Provide Testing Services of Batteries prior to shipment 2.1 All battery packs (as described above) shall be labelled with a unique identifier (serial number and test date using ISO standard date and time format) and shall be tested to meet the stated specifications prior to shipment; 2.2 At least one normal charging and discharging cycle shall be performed and the resulting battery capacity shall be recorded and documented, for each battery pack. Each test record shall be time stamped and correlate to the unique identifier specified above; 2.3 Each (bulk) shipment of battery packs shall be accompanied by the relevant test report(s). The test report shall also be made available as electronic file; and 2.4 All battery packs shall be provided fully charged. 3. Provide completely assembled NGSS camera battery packs (optional) 3.1 A complete NGSS camera battery consists out of two battery packs as specified above, installed in an NGSS battery pack enclosure according to the battery pack assembly instructions detailed in Annex A, whereby the housing will be provided by the IAEA. 3.2 Each housing for battery pack is labelled with a unique serial number. Electronic records shall be kept and made available to the IAEA with every delivered batch including the following information: 3.2.1 Serial number of the battery pack housing; 3.2.2 Date/Time of NGSS camera battery pack preparation (final testing); 3.2.3 Serial numbers of the (two) SAFT battery modules installed in each battery pack housing; 3.2.4 Result of voltage matching of the two SAFT modules installed in each battery pack housing; 3.2.5 The electronic records shall be provided in Microsoft EXCEL or any standard database format; and 3.3 The NGSS camera battery pack enclosure and housing screws are provided by the IAEA. Page 2 of 6
II. Provision of tested NGSS Annex A Assembly Instructions for a complete NGSS camera Battery Pack The Next Generation Surveillance System (NGSS) requires a battery for loss of power operations. The NGSS Battery Pack is designed specifically for this purpose. The Battery Pack is for use in the Digital Camera Module (DCM) C5 only. The Battery Pack consists of a top housing, lower housing, two (2) battery locks, a printed circuit board with a one wire EEPROM installed, and four (4) M3x30 hex screws. It is inserted into the Battery Cradle on the back of the NGSS camera housing. The Battery Pack is designed to hold two (2) Saft 7.5 V Li-Ion rechargeable batteries (2S1P INT 176065 STS, P/N 07548T) with a rated capacity of 6.8 Ah. I. Battery Pack Assembly a. Inspect the Battery Pack housing for any signs of damage. If the Battery Pack housing is damaged in any manner it should be replaced. b. Remove the four screws from the top of the Battery Pack using a 2.5mm hex wrench. Page 3 of 6
c. Separate the top and bottom housings of the Battery Pack. The Battery Pack locks can either be removed or retained in the bottom housing. d. Inspect the foam pieces in the top and bottom housing. If damaged, replace as needed. e. Measure and record the voltage of each Saft battery and record the measured value on top of each battery. Then match the batteries in pairs of equal voltage (± 0.1V). f. When installing a set of two Li-Ion batteries into a Battery Pack housing, the difference of the measured voltages must not exceed ± 0.1V. A higher voltage difference may cause a total failure of the NGSS Battery Pack. g. Being careful not to damage the foam, install a matched set of rechargeable batteries into the bottom housing. Position each battery so that the red/black wire is toward the outside of the battery housing. Page 4 of 6
h. Insert the connector from the battery into the connector receptacle on the printed circuit board. (NOTE: The connector can only fit in one direction.) i. Carefully route the excess red/black cable along the outside edge of the battery housing. Be sure to tuck the cable into the channel between the housing and the battery so the cable will not be pinched once the top cover is in place (see bottom picture). Page 5 of 6
j. Place a small amount of Loctite 5145 Tempflex sealant between the connector and the printed circuit board to secure the battery connectors in place. k. Reassemble the top and bottom housings ensuring the proper installation of the Battery Pack locks. Page 6 of 6