Battery Discharge Tester Operation Manual

Caution

The instrument must be used by qualified people strictly based on this
When plugging in and out cable, please be careful to avoid electric shock as the input and output terminals may cause discharge
Connect cables correctly. Connect the device with ground first and then to connect with other
The product should not be used beyond rated
Please turn off power when test finished or persons
Please make sure the equipment is up before opening the box. Don’t beat equipment
Put the equipment in dry, clean, ventilative and no corrosive gas indoor places. Piled putting is not allowed if there is no wooden
Panel should be up in storage. Underlay moisture-proof stuff at the bottom of equipment to prevent

1. Warranty

The warranty applies to the original purchaser that the equipment will be free of any defect in materials or workmanship for a period of two years from the date of purchase. The warranties only cover defects arising under normal use and regular service, excluding any faults and damages resulting from abuse misuse, alteration, improper installation, neglect or adverse environmental condition, not from quality problem.

Any faults of products you may be asked to take some time on the phone or by e-mail with our technical engineer. First you can submit an application, explain and description the issues, then our engineer will offer remote assistance. If this issue could be solved, we will authorize you to return the equipment to us after communicating. Equipment mush be packed in original packaging and all shipped items must be prepaid and insured.

General Information

Uninterrupted power supply is the basic protection for running all the equipment and network systems of constantly improved Informa ionization and automation. Whether it is AC or DC uninterrupted power supply system, battery as a backup power supply in the system plays an extremely important role. At ordinary times, battery is in the floating charge standby state, but once the AC power blacks out or other accidents occur, the battery will become the only power supply of the load.

It is known that battery has normal service life cycle, but it often has premature function failure due to such quality problems as material defect, structure defect or process defect, or improper use, etc. To test the standby duration and actual capacity of battery group and to ensure the normal system operation, the checking discharge test is conducted on the battery group on a regular basis or as needed according to the maintenance procedures of the power supply system, so that individual cell that has or is close to function failure can be detected in an early stage for replacement, thus guaranteeing the effectiveness of the whole battery group, or the expected life of the battery group is evaluated.

After years of R&D, the company has developed a series of highly intelligent battery charge and discharge tester with proprietary technology. This tester can be used as the discharge load in the battery off-line state, and realize the constant discharge of the set value by continuously regulating the discharge current. When discharging, the tester will automatically stop discharging when the voltage on the battery group terminal or the cell falls to the set lower limit value, or when the set discharging time is out, or when it reaches the set discharging capacity. In the meantime, the tester records all valuable and continuous real-time data during the process.

The tester has a very friendly man-machine interface, which not only enables a variety of settings and data check under the menu prompt, but also stores the discharge process data in the memory that can be archived to the USB flash drive through the data interface. Such data can be analyzed through special software in upper computer to generate the curves and reports needed.

This instrument has perfect protection function, with sound and light alarm and clear interface prompts.

Features

PTC ceramic resistor is used to avoid red heat for a safer discharge
Multi-functions such as capacity test, stop discharge, parallel operation, on-line compensating discharge for complex site
PC software in upper computer can record and analyze the total voltage, discharge current, each cell voltage and other data, and generate the data reports accordingly, to visually show the battery group performance curve, graph, report, and for printing and check.
USB interface of the tester can store the data of the discharge process into the USB flash drive, which then is imported into PC. The PC data management software can analyze the battery discharge process and generate corresponding data reports, further facilitating the data transfer and
Intelligent SCM ARM control, 7-inch 1024*600 HD LCD display, capacitive touch control operation, built-in Chinese-English switch menu, and simple and clear menu
Automatic stop protection function, over-temperature protection, over-voltage protection, over-current protection, reverse wiring protection, alarm prompt on screen upon any alarm stop, and automatic switch-off of the air circuit breaker.
Several discharges stop condition include battery string stop voltage, discharge capacity, discharge time to ensure safe
Online compensated charging/discharging can be carried out, and the discharge test can be carried out on the online working battery through an externally connected current clamp sensor, which greatly facilitates the testing work. This feature is especially suitable for applications where there is only a single set of backup

Specification Parameters

Discharge voltage	DC 38-132V
Discharge current	0-200A
Protection performance	over voltage, undervoltage, overcurrent, reverse wiring protection, 65℃ overtemperature protection, with LCD prompt and buzzer alarm
Control precision	Discharge current≤±1%; group terminal voltage≤±0.1%;
PC communication	RS485 interface, USB interface
Data storage capacity	Built-in SD card with a capacity of 8G and the USB flash drive with a capacity of 16G
Work Environment
Heat radiation	Forced air cooling
Temperature	Working rage: -5-50℃ Storage temperature: -40-70℃
Humidity	Relative humidity 0-90% (40±2℃)
Elevation	Rated elevation of 4,000m
Noise	﹤75dB
Working Power Supply
Voltage	Power supply: single-phase AC220V (-20%-+30%), frequency: 45-65Hz; charging power supply: refer to nameplate parameters or case label
Electric strength test	Input-housing: 2200Vdc 1min Input-output: 2200Vdc 1min Output-housing: 700Vdc 1min
Safety	Compliance with EN610950

2. Basic Working Principle

Battery Measurement Principle

Due to the complexity of battery electrochemical reaction, and different materials, structures, manufacturing processes and service environmental conditions, the characteristics of batteries from different manufacturers vary significantly. Even batteries produced by the same manufacturer are discrete to a certain extent. Up to now, there is no simple and effective method in the world that can quickly and accurately determine the battery performance. Battery performance test and failure prediction is still a very complex problem in electrochemical measurement.

The state of stationary acid-proof and explosion-proof lead-acid battery, which has been widely used in electric power, communication, finance, transportation and other industries, can be learn by measuring the terminal voltage, and checking the electrolyte density, liquid level and temperature. However, the seal and barren liquor design of valve regulated lead-acid (VRLA) battery makes it difficult for us to learn about whether it is in a healthy status. The test methods of explosion-proof battery are no longer applicable to VRLA battery, which is the shortcoming and difficulty of current battery operation management.

At present, the common test method is to measure terminal voltage of battery and carry out the discharge capacity test every year. We think that

The terminal voltage of battery under floating charge has no correspondence with the

capacity.

It is known that battery of poor performance may be measured for the qualified terminal voltage under floating charge. So, the terminal voltage under floating charge cannot truly reflect the battery performance.

Full capacity discharge test is still the most accurate and effective method to test the actual capacity of battery

The capacity of a battery group equals that of the worst of battery group. The test of battery group can be changed to the test of the delayed battery. The capacity of the battery group is to test by detecting the poor battery and measuring its capacity.

Discharge the battery group at a specified constant current and monitor the voltage of each battery. When the voltage of any of batteries falls to the cut-off voltage, the capacity is the actual capacity of the battery group. This method can test for the true and accurate result.

The battery has the following discharge curve:

From the battery discharge curve, it can be seen that

The same discharge curve reflects the same battery performance. The characteristic curve of the same specification battery is the same for the same manufacturer, the same formula and the same production process (the discreteness in production is not considered temporarily).
The discharge curves of cells in the same group follow different discharge rates due to their different capacities. When the battery group is discharging, each cell has a different capacity but the same discharge current, so each is discharging at a different discharge rate. It is obvious that the discharge curves of different discharge rates are followed during

Constant Current Principle

The tester’s discharge circuit adopts PWM + PID closed-loop control technology under the control of ARM (central processing unit), which enables the power circuit to work accurately under the set discharge current. For example, during constant current discharge, when battery voltage starts to decline, the ARM controller receives the reduced current value through the feedback current sensor, and then acquires the increased value of the needed controlled power loop through a certain rate and mode of calculation. This adjustment process repeats itself to ultimately achieve the effect of real- time adjustment. This is the principle of constant current discharge. According to this principle, constant power is similarly adjusted, except that in addition to the current value the voltage value is required.

3. Equipment Dimensions, Weight, Interface and Packing Instructions

Equipment Panel Interface

As shown below:

4. Measurement Condition

Operation environment

Without corrosive, explosive and insulating gas and conductive dust

Battery Discharge Tester and battery string connection

Plug quick connector of discharge cable into the quick socket of the tester respectively (red for positive and black for negative). Please DO NOT connect the positive and negative poles in the wrong way. In case of wrong connection, there will be buzzer alarm sound and text warning on the display screen: battery poles connection reversed!

Online Compensated Charging/Discharging

The conditions of online compensated discharge test are as follows:

The battery is not detached from the load;
The output of the UPS is disconnected;
Discharge current is greater than load current.

This test method is particularly suitable for occasions where there is only a single group of standby batteries and the batteries are not expected to be separated from the load during the test.

During the test, if there is an unexpected power failure, the battery can still be automatically switched to the load side for power supply, and the tester can automatically stop discharging because the actual current is greater than the set current.

Hall element current clamp is required for online compensated test. Wiring diagram is as follows:

Working Principle:

Set the battery discharge current as the discharge current of the tester master, and the internal load will automatically decline according to the current value detected by the clamp current sensor, so as to ensure that the charge and discharge current/power of the battery equals that displayed by the tester.

Master displayed current (25A) = battery group charge and discharge current (25A) = master internal discharge (16A) + actual load current (9A). Since the actual load current during online discharge varies with the online voltage, the discharge current inside the master also automatically adjusts in order to ensure the battery group to discharge in the real constant current/constant power mode.

(Note: Please adjust the output voltage of the rectifier to 0 or turn it off during the online compensated discharge test, otherwise the discharge current will come from the output of the switching power supply. The other operations are the same as the checking discharge test.

5. Interface Function Introduction

Test and Template Selection

According to the test you need, click the icon to enter the test interface.

Before entering the test interface, the system automatically guides you to select template parameters according to the preset 6 template parameters, as shown in the table below:

If needed, you can click MODIFY BUTTON to modify the relevant parameters in the corresponding module. If not, click CONFIRM BUTTON to enter the corresponding test interface, as shown in the table below:

[ROOM ID]: Input according to the parameter of tested battery. [GROUP ID]: Input according to the parameter of tested battery.

[TESTER_NAME]: Input according to the parameter of tested battery. This value will be part of the title of data recording file generated to tell which tester has carried out the test for the data file, or filled in the title of data file for other specific purpose.

[DIS MAX A/A]: The maximum value of the discharge current tested. If the current exceeds this value during the discharge process, the discharge will be cut off automatically and a prompt of “discharge current failure” will be reported.

[CHG MAX A/A]: The maximum value of the charge current tested. If the current exceeds this value during the charge process, the charging will be automatically cut off and a prompt of “charge current failure” will be reported.

[CELLS]: The total number of batteries connected to all cell monitoring boxes.

[CELL MONITOR]: Switch of cell monitoring function. When the value is 1, the cell voltage data is collected and displayed. When the value is 0, there is no display, and there is no such prompt as “cell voltage too low” if the cell voltage is 0.

[CELL ORDER]: There are two options, i.e., “starting from the positive pole” and “starting from the negative pole”, respectively meaning that the position of 1# battery in the whole group is the total positive pole or the total negative pole.

[MODULES]: The total number of cell monitoring modules used. The number must be greater than or equal to the “CELLS”/12.

[COMM. MODE]: This option is generally set to “WLS” (wireless) mode.

[INTERVAL]: The interval between data recording storage. There are six options, “1min”, “2min”, “5min”, “10min”, “30min” and “60min”. Note: the selected time interval is no greater than the measured duration/400 (maximum number of data recordings). For example, if test duration is 10h, the recording interval is 1min, then a total of 600 data recordings (10h*60min=600min) are generated in the whole test process, which exceeds the maximum 400, and thus the charge/discharge process will cut off in about 6 hours (400/60=6.67) in advance due to “recording files exceed the limit”. [NOR. CAP/Ah]: Select according to the rated group voltage of the tested battery.

[GROUP VOLT]: Select the rated voltage option for the tested battery group. The options are “12V”, “24V”, “36V”, “48V”, “72V”, “110V”, “220V”, “240V”, “380V”, “480V” and “600V”.

DO NOT choose the wrong option as it will determine the maximum value of the waveform chart on the charge/discharge interface!

[CELL VOLT]: Select the rated voltage option for the tested battery group. The options are “2V”, “4V”, “6V” and “12V”.

[CT MODE]: Options of “Internal Current Sensor” and “External Current Sensor”. The “External Current Sensor” must be selected when the online charging and discharging function is used. Otherwise, it is the “Internal Current Sensor”. DO NOT choose the wrong option!

[Allow Bad Cells]: During the charge/discharge test, if the number of cells, the voltages of which are lower than the “minimum cell voltage”, exceeds this value, the charge and discharge tester will automatically stop discharging and report “low cell voltage”.

After modifying the corresponding template parameters, click RETURN button to go back to the template option interface, and then click CONFIRM button to enter the corresponding test interface.

Discharge Operation

Before the discharge test, please fill in the correct parameters and alarm termination test values according to the battery parameters in the actual operating conditions, so that the system can make appropriate judgments according to the parameters your input.

[Ah LIMIT/Ah]: If the discharged capacity is greater than the set value during the discharge process, the system will stop discharging and report the discharge capacity completed.

[TIME LIMIT/HM]: If the discharge duration is longer than the set value during the discharge, the system will stop discharging and report that the discharge time is out.

[CELL L LIMIT/V]: If the “Allow Bad Cells” in the test template is set to 1, and the minimum cell voltage is lower than this set value during the discharge process, the system will stop and report the cell voltage is low. If the “Allow Bad Cells” in the test template is greater than 1, for example 5, then the tester will automatically stop and report the cell voltage is low when the cells of voltage below this value is greater than or equal to 5.

[GROUP L LIMIT/V]: If the group voltage is lower than the set value during the discharge, the system will stop and report the group voltage is low.

[CURRENTLY SET/A]: The set discharge current when a constant current is discharged. [POWER SET/W]: The set discharge power when discharging at constant power.

[CELL V]: Click this button to switch to the cell voltage display interface. Press “RETURN” in the lower right corner of the cell voltage display interface, and return to this page.

[PAUSE]: During the discharge process, the discharge process will pause and the data will stop recording when this button is pressed. Press this button again to return to the discharge process. [START]: This button integrates the Start, Stop and Reset, and can prompt operation in real time. For example, this button will change to “Reset” in case of alarm; it will display “Start” when the tester stops; it will display “Stop” when the tester runs.

The tester’s discharge function has two discharge modes, i.e., “constant current” and “constant power”, which are respectively introduced as follows:

Constant Current Discharge Interface

Note: When the discharge mode is changed to “constant current”, the discharge parameter setting is displayed as “CURRENT SET/A”.

Constant Power Discharge Interface

Note: When the discharge mode is changed to “constant power”, the discharge parameter setting is displayed as “POWER SET/W”.

Charge Operation

[Ah LIMIT/Ah]: If the charged capacity is greater than the set value during the charge process, the system will stop charging and report the charge capacity completed.

[TIME LIMIT/HM]: If the charge duration is longer than the set value during the charge, the system will stop charging and report that the charge time is out.

[CELL H LIMIT/V]: If the “Allow Bad Cells” in the test template is set to 1, and the maximum cell voltage is higher than this set value during the charge process, the system will stop and report the cell voltage is high. If the “Allow Bad Cells” in the test template is greater than 1, for example 5, then the tester will automatically stop and report the cell voltage is high when the cells of voltage above this value is greater than or equal to 5.

[GROUP H LIMIT/V]: If the group voltage is higher than the set value during the charge, the system will stop and report the group voltage is high.

[CURRENTLY SET/A]: The set charge current during charging test.

[CELL VOLT]: Click this button to switch to the cell voltage display interface. Press “RETURN” in the lower right corner of the cell voltage display interface, and return to this page.

[PAUSE]: During the charge process, the charge process will pause and the data will stop recording when this button is pressed. Press this button again to return to the charge process.

[START]: This button integrates the Start, Stop and Reset, and can prompt operation in real time. For example, this button will change to “Reset” in case of alarm; it will display “Start” when the tester stops; it will display “Stop” when the tester runs.

Activation Operation

The activation operation integrates all functions of charging and discharging, so the parameter setting is consistent with charging and discharging respectively, without further introduction here. Instead, the activation principle and working process are explained:

Due to the cell itself and different external conditions, the cell voltages of battery group in use are imbalanced, and the capacities stored are not equal. Therefore, in the entire charging and discharging

process of battery group, some cells are over-charged or over-discharged, which greatly reduces the service life of batteries. As a result, the active substances, mainly the negative active substance, fail in vulcanization and seriously fade in capacity, and thus it is necessary to carry out several high-current charging and discharging to activate these vulcanized active substances. This process is called activation.

For the tester itself, activation is actually a process of discharge-charge cycles, i.e., discharging first, charging, then discharging again… finally charging.

[CYCLE TIMES]: A discharging and a charging is called a cycle. Cycle times are the discharge-charge times.

[TIME USED]: The length of time the current has been consumed (discharging) or the current has been injected (charging) during a single charging or discharging process.

[Ah LOADED]: The ampere hours consumed (discharged) or injected (charged) during a single charging or discharging process.

Online Monitoring Operation

In many cases, the actual carrying capacity of a loaded battery group has to be verified, that is, it only requires to monitor the cell voltage, total voltage and total current without an actual charging and discharging test conducted on the battery group, where the online monitoring function can be used. In this interface, a total of 6 limit values can be set, namely [GROUP H LIMIT/V], [GROUP L LIMIT/V], [CELL H LIMIT/V], [CELL L LIMIT/V], [DURATION/HM] and [Ah LIMIT/Ah]. When any condition is met during the monitoring process, there will be a sound-light alarm.

During the online monitoring process, the corresponding data recording files will be generated just like in the charging/discharging process.

Data Management

Data management page is an important window interface where you can view, delete and export the automatically recorded data. First, select a data file in the left form, and then click the three buttons on the right to operate.

[Order]: The software can automatically generate a serial number for each data file according to the generated time, so that users can identify and find.

[File Name]: The name of each data file has a specific meaning, consisting of four parts – “test type” + “date (YY/MM/DD)” + “time (h/min/s)” + “tester name”. Each part is separated by an “_”.

The test types are:

Charging: “Chg.” Discharging: “Dis” Activation: “Act”

Online monitoring: “Onl”

Note: The Quick Test feature does not have data recording function. [Size (KB)]: The storage space taken up by each file in Kb.

[Num of files]: The number of all data files in the tester memory, up to 200 data files that can be managed.

[CHECK]: After selecting a data file on the left, open this data file by clicking this button to display all the recorded parameters. For details, please refer to the section [Data Check and View].

[EXPORT]: First, select a data file on the left, and save (cut) the selected data file to the root directory of USB flash drive by clicking this button. Then, the software will automatically delete the data file selected in the left form. If the USB flash drive is not recognized successfully, this operation will be cancelled automatically.

[DELETE]: Select a data file on the left, and click this button to delete it.

Data View

[File Name]: the name of the data file being viewed.

[TEST MODE]: the test types of data files being viewed, including discharge, charge, activation and online monitoring

[TESTER]: the parameter in the “Test Template” selected for the test process that generates this data file.

[ROOM ID]: the parameter in the “Test Template” selected for the test process that generates this data file.

[GROUP ID]: the parameter in the “Test Template” selected for the test process that generates this data file.

[GROUP VOLT/V]: the parameter in the “Test Template” selected for the test process that generates this data file.

[CELL VOLT/V]: the parameter in the “Test Template” selected for the test process that generates this data file.

[CELLS]: the parameter in the “Test Template” selected for the test process that generates this data file.

[MODULES]: the parameter in the “Test Template” selected for the test process that generates this data file.

[MONITOR]: the parameter in the “Test Template” selected for the test process that generates this data file.

[CELL ORDER]: the parameter in the “Test Template” selected for the test process that generates this data file.

[COMM. MODE]: the parameter in the “Test Template” selected for the test process that generates this data file.

[INTERVAL]: the parameter in the “Test Template” selected for the test process that generates this data file.

[NOR. CAP/Ah]: the parameter in the “Test Template” selected for the test process that generates this data file.

[DIS. MODE]: the parameter in the “Test Template” selected for the test process that generates this data file.

[DIS. MAX CURRENT/A]: the parameter in the “Test Template” selected for the test process that generates this data file.

[CHG. MAX CURRENT/A]: the parameter in the “Test Template” selected for the test process that generates this data file.

[CT MODE]: the parameter in the “Test Template” selected for the test process that generates this data file.

[PARALLEL]: the parameter in the “Test Template” selected for the test process that generates this data file.

[MASTER/SLAVE]: the parameter in the “Test Template” selected for the test process that generates this data file.

[SLAVE ADDRESS]: the parameter in the “Parameter Setting” interface selected for the test process that generates this data file.

[NUM OF SLAVE]: the parameter in the “Parameter Setting” interface selected for the test process that generates this data file

[WIRELESS BAND]: the parameter in the “Parameter Setting” interface selected for the test process that generates this data file

[Ah LIMIT/Ah]: the parameter in the interface of one of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[TIME LIMIT/HM]: the parameter in the interface of one of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[CELL L LIMIT/V]: the parameter in the interface of one of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[GROUP L LIMIT/V]: the parameter in the interface of one of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[CURRENTLY SET/A]: the parameter in the interface of one of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[BAD CELLS ALLOW]: the parameter in the “Test Template” selected by the test process that generates this data file.

[REMOTE]: the parameter in the interface of one of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[BAD CELLS]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[STOP VOLT]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[STOP CURRENT]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[CAP. DISED]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[TIME DISED]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[MIN CELL 1]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[MIN CELL 2]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[MIN CELL 3]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[MIN CELL 4]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[MIN CELL 5]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[MIN CELL 6]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[STOP RESON]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[Num Of Records]: the parameter upon stops of the test processes of charging/discharging/activation/online monitoring that generates this data file.

[Start Volt/V]: the first recorded parameter in the cell voltage data that generates this data file. [Stop Volt/V]: the last recorded parameter in the cell voltage data that generates this data file. [Resistance/mR]: the internal resistance value estimated from the recorded parameters.

[CURVE:] click this button to enter the “Data Curve” page.

Calibration

In many cases, the current sensor or voltage collector has a certain deviation due to the vibration during transportation or influence of environmental temperature and humidity, so the calibration is required.

After clicking the [CALIB] on the Main Page, enter the default password 13982 in the dialog box, and then click [OK] to enter the [CALIB] page.

Window of Enter Password

In the calibration page, 3 values, i.e., charge current, discharge current and voltage, can be calibrated respectively. Before the calibration, 4 parameters must be recorded in advance: actual value 5% and displayed value 5%; actual value 95% and displayed value 95%.

These 4 parameters must be recorded in the actual test process. Set the charging/discharging parameters of the tester to 5% and 95% respectively. (5% and 95% here are just rough figures, not necessarily accurate to the percentage, which the software will automatically identify and correct). Take 220V1000A tester for example: when the discharge current is set to 5A, record the reading (actual value) on the calibration meter (such as clamp meter), and then when the discharge current is 95A, record the reading (actual value) on the calibration meter (such as clamp meter).

[CURRENT CALIBRATION]: First select the calibration mode of charging or discharging, fill in the 4 values recorded previously, click [CURRENT CALIBRATION], click OK in the dialog box popped up to confirm, and then the calibration is completed. The dialog box and test interface will be automatically closed to return to the Main Page. The dialog box for confirmation is as follows:

System Setting

[PARALLEL]: When a single tester is unable to meet the needs of charging/discharging power, parallel test can be carried out. [PARALLEL] should be set “on” for parallel test, and “Off” for non-parallel state. [MASTER/SLAVE]: The parallel operation has master mode and slave mode. In parallel operation, it is only required to set the relevant charge and discharge parameters of the master, set the slave’s [PARALLEL] “on”, and set [MASTER/SLAVE] as “Slave”. Then, fill in the slave address.

[SLAVE ADDRESS]: When the parallel operation is on and [MASTER/SLAVE] is set as “Master”, the “NUM OF SLAVE” is displayed here; when [MASTER/SLAVE] is set as the “Slave”, the “SLAVE ADDRESS” is displayed here from 1 up to 10.

[WIRELESS BAND]: set the communication band between the tester and the wireless cell module. Only the cell voltage collectors with the same band can communicate with the tester.

[REMOTE CONTROL]: The remote-control function is needed when the remote upper computer, such as PLC, touch screen, PC upper computer software or similar configuration software, is used to control the charge and discharge. This function requires to connect with the tester RS485 interface, because wireless communication is unavailable.

[LANGUAGE]: When you need to switch the tester display language, you can select in this option. Currently, only Chinese and English are supported. It will take effect only after a restart.

Schematic Diagram of Parallel Operation

Note: For parallel control, the connecting interface requires a 6-pin crystal plug, which is optional. Please contact the sales staff when ordering.

Schematic Diagram of Remote-Control Operation

Note: For remote control, the connecting interface is a DB9 socket with RS485 interface. Pin 1 of DB9 is A and Pin 2 is B.

Time Setting

When the time of the local system needs to be changed, click [Time Setting] in the [System Setting] interface, and the time setting dialog box will pop up. After the time drop-down list is set, click [OK] to validate immediately.

View Online Helpfile

Online helpfile is designed to facilitate a quick and easy view of the technical parameters and principal documents.

Click any of the 20 chapters, and the supporting information will pop up. Press RETURN to go back.

Restart

When the system language is changed or the system needs upgrading, the system can be restarted via the [Restart] button on the Main Page, or by switching off the working power and powering on again.

System Update via USB Flash Drive

When the system needs updating remotely, the local update file, called Charge_ Discharge. bin, can be obtained from the manufacturer or supplier.

The update steps are as follows:

Step 1: Put the update file into the System folder of the USB flash drive as shown in the figure below:

Step 2: Insert the USB flash drive into the USB port in the tester front panel. Under normal conditions, the title bar will display the USB icon, which means the USB flash drive is recognized successfully.

Step 3: Click [Restart] on the Main Page, or re-power the tester, and it will automatically enter the update interface as shown in the figure below:

After the update is completed, it will automatically return to the Main Page. Then, the update file in the USB flash drive must be deleted, otherwise every time you insert the USB flash drive, the system will restart.

6. Common Failures and Troubleshooting Methods

No.

Failure

Troubleshooting Method

The discharge air breaker cannot

be switched on.

The master working power is not turned on, or the

battery voltage is beyond the rated range.

The tester keeps alarming after being connected to the high-

current lead.

Check whether the positive and negative poles, and whether the voltage range are within the nameplate

rated voltage range.

The cell voltages of a certain module are all 0.

Check and confirm whether the cell monitoring switch in the test template interface is “on”.

Check and confirm whether the module communication mode in the test template interface is “WLS” (wireless).

The cell module address setting is out of range. The band setting of the cell module is inconsistent with the master.

Wiring error of cell module.

The wiring of cell module falls off.

Multiple masters are set to the same band in the same area.

If the cell module is damaged, contact the after-sale

technical personnel.

The cell voltage sequence does

not correspond to the actual

Check and confirm whether the battery order in the

test template interface is consistent with the actual

battery.

batteries wired.

The cell monitoring page shows that the number of cell voltages does not correspond to the

actual voltages applied.

Check if the set values of “CELLS” and “MONITORING MODULES” on the test template page are correct.

“Discharge current failure” is displayed during discharge.

Check whether the discharge switch is on.

The current during discharge exceeds the maximum

value set in the test template page.

“Overtemperature failure” is displayed during discharge.

Check that each cooling fan rotates normally. Ensure that the working environment is well ventilated.

Ensure the inlet and outlet of the tester are not close to the wall or other equipment, keeping a distance of at least 1m.

The ambient temperature is too high, over 45℃, and

the ventilation is poor.

The discharge current is normal during discharge, but the voltage

does not drop.

Ensure the battery group is not disconnected from the charging system.

The total voltage cannot be collected by discharge.

The total voltage collection line is not wired, or is reversed, or there is a broken line in the collection

wiring.

Prompt “Recording files exceed the maximum number” during charging/discharging.

The maximum records of a single file are 400, so do not set the intervals too short when the charge and discharge continues for a long time. For example, the discharge time is 10h (600min), and the interval is set as 1min (a total of 600 records required), this fault will be prompted in about 400min (6h40min). Set the

interval to 2min.

After plugging in the USB flash drive, the system will be automatically updated every

time it is powered on.

After updating the system via the USB flash drive, you must delete the update file in the USB flash drive, or you will automatically enter the automatic update

program every time you plug it in.

Report “Memory storage

failure” during discharge

SD card gets loose or fails. Please contact after-sales

technical personnel for solution.

After the USB flash drive is

plugged in, the title bar does not display “USB” prompt.

The USB flash drive has a file system in a wrong

format, or is damaged. Please format the file system as FAT32.

The current shows no increase after the discharge starts, but the actual current keeps

increasing.

Select the wrong internal and external current sensors in the test template page.

Semco SI BDS 132V 200A