8-Channel 5V6A Battery Testing System for Lithium-Ion Cell Cycling and Capacity Grading | TOB-CT-4008Q-5V6A-S1

Product Overview and Ideal Applications

The TOB-CT-4008Q-5V6A-S1 is a multi-channel battery testing system designed for charge-discharge cycling, capacity grading, DCIR measurement, and pulse testing of lithium-ion cells within a 5 V / 6 A / 30 W per-channel operating envelope. The system provides independent control on every channel, with each channel built around a dual closed-loop structure - one loop for the constant current source and one for the constant voltage source - and four-wire data acquisition that eliminates the influence of lead and contact resistance on the measured voltage.

The channels operate across four switchable current ranges - 100 mA, 500 mA, 3 A, and 6 A - with a minimum output current of 0.2 mA. This range structure gives the system a wide dynamic range: low-current characterization at the milliampere level, and full 6 A cycling for cells that demand it, without changing hardware. Voltage output spans 25 mV to 5 V, covering the full operating window of lithium-ion single cells. The measurement chain uses 24-bit AD and 16-bit DA conversion, with current response time within 1 ms and charge-to-discharge conversion time within 40 ms; data is recorded at a 10 Hz frequency (100 ms minimum interval).

Beyond basic cycling, the TOB-CT-4008Q-5V6A-S1 supports DCIR testing and pulse charge/discharge programs - in current or power mode, with a minimum pulse width of 500 ms and up to 32 pulses per step. On the software side, test data is managed through a MySQL database over a TCP/IP connection, with exports in EXCEL, TXT, GRAPH, PDF, and CSV formats. Optional CAN and RS485 communication - including BMS communication with DBC configuration - allows the system to exchange data with battery management systems for pack-level and BMS-integrated testing programs.

Ideal for:

• Battery cell manufacturers performing capacity grading, sorting, and cycle-life testing of cylindrical cells (including 18650, 21700, and 26650 formats) and pouch cells within the 5 V / 6 A / 30 W limits.
• Battery R&D laboratories evaluating electrode materials and cell designs across four current ranges, from low-current characterization to 6 A cycling, on one instrument.
• Quality-control and incoming-inspection laboratories that require traceable test data with database management and standardized export formats.
• Pack and BMS developers using the optional CAN / RS485 / BMS communication interface to test cells and packs with real-time BMS data exchange.

Need to confirm whether the 5 V / 6 A per-channel envelope and fixture configuration match your cell format and test protocol? Contact our battery testing engineers with your cell specification and test plan.

Where Battery Testing Fits in Cell Manufacturing and R&D

In the lithium-ion cell manufacturing chain, cell-level charge-discharge testing serves two principal roles:

• Capacity grading and sorting (production): After formation, cells are cycled to measure their actual capacity, internal resistance, and self-discharge characteristics, and are sorted into capacity bins. Grading determines which cells are matched into a battery pack - a step that directly affects pack performance and life. The TOB-CT-4008Q-5V6A-S1 performs this function for cells within its power envelope, with independent channel control allowing multiple cells to be graded in parallel.
• Performance and life testing (R&D and QC): During development and quality verification, cells are cycled under controlled protocols to measure capacity retention, rate capability, and DCIR growth. The four-range architecture means the same system can run a low-rate characterization and a high-rate cycling program without switching equipment.

The system's DCIR function supports internal-resistance measurement under load - a key parameter for power-capable cells - while the pulse charge/discharge program supports protocols that emulate real-world load profiles. For teams working with battery management electronics, the optional BMS communication interface extends testing from the bare cell to the pack level, with DBC configuration enabling message-level integration.

Key Engineering Characteristics of the TOB-CT-4008Q-5V6A-S1

• Independent Multi-Channel Control with Dual Closed-Loop Sources - Each channel pairs an independent constant current source and constant voltage source in a dual closed-loop structure, with independent channel control. This architecture holds voltage or current precisely during the transition between CC and CV phases - the critical point of any charge protocol. Channel parallelism is not supported, so channels are applied to individual cells.
• Four Current Ranges from 100 mA to 6 A - The 100 mA / 500 mA / 3 A / 6 A range structure, combined with a 0.2 mA minimum output current, gives the testing system a wide dynamic range. Small cells and low-current characterization tests run on the low ranges; 6 A cycling - sufficient for high-capacity cylindrical cells - runs on the top range, with CV cut-off currents scaled per range (0.1 mA / 0.5 mA / 3 mA / 6 mA).
• Four-Wire Data Acquisition - Voltage and current detection use a four-wire (Kelvin) connection, separating the current-carrying path from the voltage-sensing path. This preserves measurement accuracy at the cell terminals regardless of lead and contact resistance - a fundamental requirement for accurate capacity and DCIR data.
• 24-Bit AD / 16-Bit DA Measurement Chain - The 24-bit AD and 16-bit DA conversion, with voltage and current accuracy of ± 0.01 % of FS and power accuracy of ± 0.02 % of FS, provide the resolution and repeatability needed for reliable grading. Data is recorded at 10 Hz (100 ms minimum interval), and current response time is within 1 ms (10 % ~ 90 % of FS) with charge/discharge conversion within 40 ms (-90 % ~ 90 % of FS).
• Pulse Testing and DCIR - Pulse charge/discharge programs run in constant current or constant power mode, with a minimum pulse width of 500 ms and up to 32 pulses per step, and cut-off by voltage or relative time. DCIR testing is supported, enabling internal-resistance measurement under defined current pulses.
• Comprehensive Protection, Software and Hardware - Software protection allows settable safety conditions - voltage upper/lower limits, current upper/lower limits, and additional parameters - while hardware protection covers anti-reverse connection, over-voltage, over-current, and over-temperature. These layers protect both the cells under test and the instrument during long-duration cycling.
• Database-Managed Data with Standard Export Formats - Test data is managed through a MySQL database with TCP/IP host communication. Results are exportable in EXCEL, TXT, GRAPH, PDF, and CSV formats, supporting quality documentation and downstream analysis.
• Optional CAN / RS485 / BMS Communication - An optional communication expansion supports CAN and RS485 communication, including BMS communication with DBC configuration - extending the testing system to programs where the battery management system participates in the test.

Technical Specifications

1. General

2. Voltage

3. Current

4. Power

5. Time

6. Working Mode

7. Cycle

8. Protection Mode

9. Communication and Computer Configuration Requirements

10. Operation and Storage Environment Requirement

11. Fixture specifications and equipment dimensions

Practical Testing Recommendations

• Wiring and fixtures: Connect cells using the specified four-wire scheme to preserve voltage measurement accuracy. Per the specification, the minimum discharge voltage achievable depends on the connection - 1 V with the upper and lower fixture, 1.5 V with a 2 m line length - so keep the connecting leads at the specified length and avoid unnecessary extension.
• Range selection: Select the current range that matches the test plan. Low-current characterization and small cells belong on Range 1 (100 mA); 6 A cycling belongs on Range 4, where the CV cut-off current scales to 6 mA accordingly.
• Protection setup: Configure the software protection conditions - voltage upper/lower limits and current upper/lower limits - before starting long-duration cycling, so an anomalous cell is cut off automatically rather than damaging the channel or the cell.
• Pulse and DCIR programs: For pulse testing, note the 500 ms minimum pulse width and the 32-pulse limit per step; pulse steps are cut off by voltage or relative time. DCIR measurement should be run under consistent current and timing conditions to make results comparable between cells and batches.
• Data management: Operate the system through the TCP/IP host connection and back up the MySQL database periodically. Export data in EXCEL, TXT, GRAPH, PDF, or CSV formats per your quality-records requirements.
• BMS-integrated testing (optional): When using the optional CAN / RS485 / BMS communication, prepare the DBC configuration file so that BMS messages are correctly interpreted by the test software.

Engineering FAQ

Q1: What types of cells can the TOB-CT-4008Q-5V6A-S1 test?

Any cell that operates within the system's envelope: up to 5 V and 6 A per channel, with a maximum single-channel output power of 30 W. This covers most single-cell testing applications - cylindrical cells such as 18650, 21700, and 26650 formats, and pouch cells - as well as low-current characterization on the 100 mA range thanks to the 0.2 mA minimum output current. Channel parallelism is not supported, so each channel is used for one independent cell.

Q2: What is the benefit of the four current ranges?

A single range cannot serve both milliampere-level characterization and 6 A cycling with good accuracy. The 100 mA / 500 mA / 3 A / 6 A structure lets the testing system run each test on the range where the measurement is most accurate - with CV cut-off currents scaled per range (0.1 mA to 6 mA) - so one instrument covers everything from small-cell evaluation to full 6 A cycling.

Q3: What pulse and DCIR capabilities does the system support?

Pulse charge/discharge programs can run in constant current or constant power mode, with a minimum pulse width of 500 ms and up to 32 pulses per step, cut off by voltage or relative time. DCIR testing is supported, providing internal-resistance data for power-capability evaluation and grading.

Q4: Can the system test battery packs or communicate with a BMS?

The optional communication expansion supports CAN and RS485 communication, including BMS communication with DBC configuration. This allows test programs in which the battery management system participates - defined by the customer's BMS protocol and the DBC file - while the base system continues to perform cell-level charge-discharge, pulse, and DCIR testing.

Q5: How is test data managed?

Test data is stored in a MySQL database managed by the host software, connected over TCP/IP, with exports in EXCEL, TXT, GRAPH, PDF, and CSV formats. Software protection conditions (voltage and current limits) are settable in the same environment, and hardware protection - anti-reverse connection, over-voltage, over-current, and over-temperature - operates independently.

Q6: What operating conditions does the system require?

Operating temperature 0 °C ~ 40 °C and operating humidity ≤ 70 % RH without moisture condensation; storage at -10 °C ~ 50 °C and ≤ 80 % RH. Within 25 ± 10 °C, the accuracy offset caused by temperature is less than 50 ppm/°C. The system is rated IP20 and should be installed in a clean, dry, well-ventilated location.

Ready to add reliable, multi-channel cell cycling and grading capacity to your laboratory or production QC line? Request a quotation for the TOB-CT-4008Q-5V6A-S1, specifying your cell format, test protocol, and whether the optional CAN / RS485 / BMS communication is required. Our battery testing engineers can advise on fixture selection and test-program setup.

tob.amy@tobmachine.com | +86 181 2071 5609

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