MSG Equipment MS800 User manual

2022.12.27
MS800
TESTER FOR DIAGNOSTICS OF BATTERY HYBRID
AND ELECTRIC VEHICLES
USER MANUAL
TESTER DO DIAGNOSTYKI AKUMULATORÓW POJAZDÓW
HYBRYDOWYCH I SAMOCHODÓW ELEKTRYCZNYCH
INSTRUKCJA OBSŁUGI
ТЕСТЕР ДЛЯ ДИАГНОСТИКИ БАТАРЕЙ ГИБРИДНЫХ
АВТОМОБИЛЕЙ И ЭЛЕКТРОМОБИЛЕЙ
РУКОВОДСТВО ПО ЭКСПЛУАТАЦИИ
UNIQUENESS
TRAINING
SERVICE
INNOVATIO
N
WARRANTY
QUALITY

English
User manual
3
CONTENT
INTRODUCTION....................................................................................................................................................4
1. APPLICATION....................................................................................................................................................4
2. SPECIFICATIONS..............................................................................................................................................5
3. TESTER COMPLETE SET..................................................................................................................................6
4. TESTER DESCRIPTION....................................................................................................................................6
4.1. Tester menu........................................................................................................................................... 7
4.1.1. Settings menu for Ni-Mh battery diagnostics...................................................................10
4.1.2. Settings menu for Li-Ion battery diagnostics...................................................................14
5. APPROPRIATE USE........................................................................................................................................16
5.1. Safety Guidelines ............................................................................................................................... 17
5.2. Tester installation and connection............................................................................................... 17
6. BATTERY DIAGNOSTICS...............................................................................................................................18
6.1. Diagnostics of Ni-Mh modules.......................................................................................................18
6.2. Recommendations for charging Ni-Mh batteries..................................................................... 20
6.3. Li-Ion cell diagnostics.......................................................................................................................23
7. TESTER MAINTENANCE................................................................................................................................ 24
7.1. Tester software update.................................................................................................................... 24
7.2. Cleaning and care ..............................................................................................................................25
8. TROUBLESHOOTING GUIDE ........................................................................................................................25
9. RECYCLING.....................................................................................................................................................25
CONTACTS.......................................................................................................................................................... 26

English
Tester MS800
4
INTRODUCTION
We appreciate you have chosen the products of TM MSG Equipment.
This user manual contains the information about the application, the technical characteristics,
the operation principles of the tester MS800, as well as the methods of the evaluation of the
technical condition of the hybrid vehicle high-voltage batteries.
Before using the tester MS800 (hereinafter, “the tester”), study this user manual thoroughly. If
required, get the special training at the manufacturer facilities.
Due to the permanent improvements of the tester, the design, the supply slip and the software
can be modificated. All changes are not included in the present user manual. Pre-installed
software can be updated. Support can be terminated without prior notice in the future.
1. APPLICATION
Tester MS800 is designed for the diagnostics of high-voltage nickel-metal hydride (Ni-Mh) and
lithium-ion (Li-ion) batteries of hybrid cars and electric vehicles. The tester allows:
• determine the capacity of the battery modules;
• prepare the battery for installation on the car balancing all modules by voltage;
• prepare the module for long-term storage by charging to a certain level.
The tester provides simultaneous check (balancing) up to 36 modules. The process of diagnostics
(balancing) of battery modules is automatic. The operation and the control of the diagnostics are
carried out on the touch-screen. The diagnostic result is stored in the tester memory, and then it
can be copied to USB flash memory.

English
User manual
5
2. SPECIFICATIONS
Supply voltage, V
230
Supply mains type
Single-phase
Demanded power (max.), kW
3.5
Dimensions (L x W x H), mm
1430×300×220
Weight, kg
53
Operation
touch control
Display
9"
Battery Diagnostics
Max. channel voltage, V
for Ni-Mh
20
for Li-Ion
4.2
Charge rate, A
from 0.1 up to 4.5
Discharge rate, A
from 0.1 up to 6 (max. 50W per channel))
Measured parameters
- capacity
- voltage
- current
- temperature
Measurement accuracy:
voltage
current
0.02 %
0.5 %
Additional features:
Protection from
- reverse polarity;
- short circuit of the connected cable;
- overheat.
Diagnostics results storage
yes
Software update
yes
Connection of USB flash drive
1 x USB 2.0

English
Tester MS800
6
3. TESTER COMPLETE SET
The equipment complete set includes:
Description Quantity, pc
Tester MS800
1
Diagnostic cable
36
Network cable
1
Manual (card with QR code)
1
4. TESTER DESCRIPTION
The tester consists of the following main elements (fig. 1):
Figure 1. Tester overall view
1– Diagnostic cable connection ports.
2– Module voltage indicator.
3– Touch screen – to display the diagnostic parameters of a diagnosed battery and tester function
control.
The tester monitors the temperature of each module, during the diagnostic process. For this
purpose, each diagnostic cable (fig. 2) has a temperature sensor. The tester stops charging any
module whose temperature has exceeded the previously set permissible value. This provides
additional diagnostic process security and reduces the probability of module failure.

English
User manual
7
Figure 2. Diagnostic cable
4.1. Tester menu
The tester main menu (fig. 3) consists of:
Figure 3. Tester main menu
1 –Selection of the operating mode:
CHARGE – battery modules charging;

English
Tester MS800
8
DISCHARGE – battery module discharge;
TEST CYCLE – configurable cycle of the tester. Allows setting the sequence of operations
that the tester will automatically perform;
BALANCING – battery module balancing mode (battery module voltage balancing).
2 – Temperature readings of the tester power elements.
3– Tester cooling system pump operation indicator.
4– Indicator of the lack of the required amount of coolant in the tester's cooling system.
5 – Indicator of connected USB flash drive and internal SD card.
6 – SETTINGS button – to enter tester settings menu.
Charge/discharge control/diagnostics/balancing menu (fig. 6):
Figure 4. Battery charge/discharge control menu
1 – Button to return to the main menu.
2- Indicators of the state of connected modules.
3- Indicator of selected tester operating mode.
4- Button to start the selected tester operation mode.
5- Button to return to the settings of the selected tester operation mode.

English
User manual
9
The battery module status indicators contain the following information:
Figure 5. Battery module charge/discharge control indicator
1 – Channel operation indicators.
2– Channel sequential number.
3 – Module ongoing temperature.
4 – Module ongoing voltage.
5 – Charge/discharge current rate ongoing value.
6– The current value of the capacity ongoing of the test.
The «SETTINGS» menu includes the following (see fig. 6):
Figure 6. Tester settings menu
1 – Button to return to the main menu.

English
Tester MS800
10
2– Indications from internal sensors of the tester (information is needed by specialists of
MSG Equipment Service).
3– The slider is used to manually adjust the speed of rotation of the fans of the cooling system
of the tester.
Button «Update» is used to update the software tester.
Button «Service» – this menu is designed to test the tester by specialists MSG Equipment.
Button «Move file to USB» is used to copy saved diagnostic results to a USB flash drive
formatted FAT32.
Button «Set Data» – date setting.
Button «Set Time» – time setting.
Button «Reset setting» – restore factory settings of the tester.
4– Change the control circuit of the pump of the cooling system of the tester.
5– Touch screen setting.
4.1.1. Settings menu for Ni-Mh battery diagnostics
It is possible to select the number of cells in the module from the standard list of values or specify
your own, choosing any mode of operation with Ni-Mh batteries.
Figure 7. Menu to select the number of cells in the Ni-Mh battery module

English
User manual
11
Menu settings charge/discharge of the Ni-Mh modules contains:
Charge mode Discharge mode
Figure 8. Charge/discharge mode menu for Ni-Mh batteries
1 – Charge/discharge parameters:
Cutoff voltage 1 Cell – maximum/minimum voltage per cell.
ΔU 1 Cell – amount of voltage drop per cell at which the charge process is stopped.
Timeout ΔU –ΔU measuring delay at the charging start - to prevent the beforehand charge
stop.
Limit capacity – maximum charge capacity.
Tmax, °C –maximum module temperature above which the charging process is interrupted.
2– The value input field. Window appears with the setting, when clicking.

English
Tester MS800
12
3– Activate the trickle charge mode that will occur after the main cycle.
“Save” button – saving the settings and switching the tester to the charge/discharge mode of the
battery modules.
Ni-Mh battery module balance mode settings menu contains:
Figure 9. Menu of options for balancing Ni-Mh modules
1 – Balancing parameters:
Current balancing – current at the start of balancing.

English
User manual
13
Balancing voltage – voltage that should be after balancing the modules.
Cutoff current balancing – end current of balancing process.
Difference voltage C/D – specified difference between charged and discharge elements.
Tmax, °C –maximum temperature of the module above which the charge/discharge process
is interrupted.
2– Input field for values.
3– Information values:
Charge voltage to– Voltage to which the cells are charged.
Discharge voltage to – Voltage to which the cells are discharged.
Settings menu of cyclic mode of the tester with Ni-Mh modules contains:
Figure 10. Settings menu of cyclic mode of the tester with Ni-Mh modules
1– Customizable stages.
Five stages is the maximum that can be set, consisting of modes of operation: CHARGE, DISCHARGE,
BALANCING. Working with the Ni-Mh battery after each step (except the last) it is recommended

English
Tester MS800
14
to set an exposure of 30-240 minutes. The stage is added by pressing «+» button. The stage is
removed by pressing «X» button.
2– Set stage of the tester. Clicking on the stage field opens a window. It is an opportunity to
change the mode and settings.
4.1.2. Settings menu for Li-Ion battery diagnostics
The settings menu for the charge/discharge mode of the Li-Ion modules of the cell contains:
Charge mode Discharge mode
Figure 11. Li-Ion cell charge/discharge mode settings menu
1 – Charge parameters.
2– Input values field.

English
User manual
15
The Li-Ion cell balancing mode settings menu contains:
Figure 12. Li-Ion cell balancing mode settings menu
1 – Balancing parameters:
Current balancing – current at the start of balancing.
Balancing average voltage – voltage after balancing.
Cutoff current balancing – end current of balancing process.
Difference voltage C/D – specified difference between charged/discharged cells.
2– Input field for values.
3– Information values:
Charge voltage to– voltage to which the cells are charged.
Discharge voltage to – voltage to which the cells are discharged.

English
Tester MS800
16
The settings menu for the cyclic operation of the tester with Li-Ion cells contains:
Figure 13. Settings menu for cyclic operation of the tester with Li-Ion cells
1– Customizable stages. The maximum can be set to five stages, consisting of the modes of
operation of the tester: CHARGE, DISCHARGE, BALANCING. Stage is added by pressing «+». Stage
is removed by pressing «x»
2– Set stage of the tester. Clicking on the stage field opens a window where you can change the
mode and its settings.
5. APPROPRIATE USE
1. Use tester only for intended purpose (sect. 1).
2. Use tester in the premises equipped with the supply-and-exhaust ventilation, at the
temperature range from +10 °Сup to +30 °Сand the relative humidity range from 10 up to 75%
without moisture condensation.
3. Connection\disconnection of diagnostic cables to the battery modules must be done when the
charge\discharge or balancing mode is switched off.
4. During the charge, discharge, and balancing process, the high-voltage battery must be cool.

English
User manual
17
5. Incorrectly selected battery test parameters can lead to additional damage or failure of the
battery.
6. In case of failures in the operation, stop further operation and contact the manufacturer or
sales representative.
The manufacturer is not responsible for any damage or injury to human health resulting from
non-compliance with the requirements of this user manual.
5.1. Safety Guidelines
1. Specially trained persons who have been instructed in safe techniques and methods of
working with high-voltage batteries and have an appropriate electrical safety group are allowed
to work with the tester.
2. Turn off the tester is necessarily for cleaning and in emergencies.
3. Work area must always be clean, with good light illumination, and spacious.
4. To ensure electrical and fire safety FORBIDDEN:
- connect the tester to the electrical network having faulty protection against current
overloads or not having such protection;
- use a socket without a grounding contact;
- use extension cords;
- exploitation in defective condition;
- independently repair and make design changes, it can lead to serious damage and lose
warranty.
5. indicate the wrong module element quantity.
6. use the tester without the supervision of the special trained personnel.
5.2. Tester installation and connection
The tester is supplied packed. Once unpacked, it should be inspected to make sure it has no
damages and/or liquid leakages. If the damages and/or the liquid leakages were revealed, prior
to the equipment starting, contact the manufacturer or a dealer.
During the installation, provide the minimal gap 0.5 m on the left and the right sides of the tester,
keep 25 mm under the tester - to provide the free air circulation.
Before the operation of the tester it is necessary:
- connect the 230V electric network (single-phase) with a grounding contact and with the
presence of a protective automatic device (25A). If the socket is removed from the place of
installation, it is necessary to make adjustments to the electrical network and install the socket.
- If necessary, fill (refill) cooling liquid.

English
Tester MS800
18
6. BATTERY DIAGNOSTICS
The diagnosis of a battery means determining the capacity of its modules. To determine the
condition of the battery it is necessary to make a charge and discharge cycle of each of the
modules. We recommend that a module is considered operational if it has retained more than
70% of its original capacity.
6.1. Diagnostics of Ni-Mh modules
Determining the capacity of Ni-Mh modules includes the following steps:
1. Discharge modules to 0.9V per cell.
2. Exposure 30-60 min. Do nothing with modules.
3. Charging modules with obligatory activation of the trickle charging mode, for the maximum
degree of charging.
4. Exposure 30-60 min.
5. Discharge of modules up to 0.9V per cell. The capacity of the modules is determined.
WARNING! To prevent battery damage during the diagnosis process, it is recommended to:
•Battery diagnostics must be in the assembled state, or the battery modules be properly
compressed between themselves in any available way to prevent deformation.
•Advisable to remove all contact tires from the battery.
•Battery must be cooled by airflow in the diagnosis process.
The procedure for diagnosing modules consists of 6 cells each illustrated below.
The sequence of operations is as follows:
1. Connect the diagnostic cables to the terminals observing polarity and attach a temperature
sensor to each module of the appropriate channel.
2. Select «DISCHARGE Ni-Mh» mode. Configure the discharge current 4 - 5 A, the minimum voltage
0.9V, and the maximum temperature of the module 55°C and press the button «Save». The tester
will go to the control menu of the charging/discharging process. Make sure that all plugged-in
battery modules are determined by the tester. Click «START» to start the discharge process.
3. Do pause in the diagnostics for 30 minutes to 1 hour after the discharge.
4. Next, charge the battery. Choose «CHARGE Ni-Mh». Adjust the charge current 4A at battery
temperature 22 - 25°C, maximum voltage 1.47V, delta 1.5-2mV, and activate the charge mode.

English
User manual
19
5. After the end of the charge, pause the diagnosis for 30 minutes to 1 hour.
6. After the battery is charged, measure its capacity. Choose «DISCHARGE Ni-Mh». Configure the
discharge current 4 - 5 A, the minimum voltage 0.9V, and the maximum temperature of the module
45°C and activate the discharge mode. At the end of the discharge process, fix the capacity of
each module.
7. After determining the capacity of the modules of the battery, it must be charged, pausing
for 30 minutes to 1 hour.
WARNING! The battery must not disassemble to prevent deformation after the charge! The
battery must be allowed to cool for several hours.
If required, items 2 - 6 of the tester can be performed independently, for this configures the mode
«TEST CYCLE Ni-Mh». An example of configured mode shows in Figure 14.
WARNING! Once the tester has started the cycle, the settings cannot be changed.
If necessary, save the results of module diagnostics, connect the USB flash drive to the tester,
enter the tester settings and click «Move the file to USB».
At the end of the cycle, fix the measured cell capacity. The battery must then charge by taking a
break of 30 minutes to 1 hour.

English
Tester MS800
20
Figure 14. Configured cyclic mode tester menu
6.2. Recommendations for charging Ni-Mh batteries
Typically, Ni-Mh modules charge with a charge current of 0.5 to 1C, where C is the cell capacity in
Ah. Cell capacity ranges from 6 to 6.5A for almost all hybrid car batteries. We recommend charging
modules with a current of 4 - 4.5A (maximum for tester MS800).
There is a problem charging Ni-Mh modules in determining when the module will charge. It is
because the Ni-Mh modules of hybrid cars consist of several sequentially connected cells. It is,
therefore, impossible to control the voltage of each cell, but only voltage of the module.
Consequently, there may be a situation when the cell voltages in the module are, for example,
1.35V, 1.35V, 1.35V, 1.35V, 1.35V, 1.35V, 1.5V. The total voltage of 8.25V is normal, provided that all
cells inside have the same capacity, but 5 of them are undercharged and one, is already recharged.
Thus, the tester has four parameters that indicate that the module is already fully charged and
the charging process must stop:
1. Maximum voltage.
In the charge settings, set this voltage based on the voltage of one element, and the tester
multiplies it by the specified number of cells.