SBS SBS-6500 User manual

SBS-6500 User Manual
Storage Battery Systems, LLC.
Battery Resistance Tester
SBS –6500
User Manual
99 Washington Street
Melrose, MA 02176
Phone [phone]
Toll Free 1-800-517-8431
Visit us at www.TestEquipmentDepot.com

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SBS-6500 User Manual
Storage Battery Systems, LLC.
Contents
Notes for Safe Operation ......................................................................................... 5
: WARNING ................................................................................................................ 5
: CAUTION ................................................................................................................. 5
1. Introduction ........................................................................................................ 8
1.1. Battery Condition Determination ....................................................................... 8
1.2. Description ........................................................................................................ 9
1.3. Special Features ............................................................................................. 10
1.5. Dimensions and Weight .................................................................................. 15
2. Initial Settings before use ............................................................................... 16
2.1. Insert Test Leads ............................................................................................ 16
2.2. Power ON/OFF ..................................................................................... 17
2.3. Real Time Clock Function ............................................................................... 17
2.4. Back Light Display ................................................................................. 18
3. Measurement .................................................................................................... 19
3.1. “0” Point Adjustment Before Measurement ..................................................... 19
3.2. “0 ADJ“ 0 Adjustment Procedure (Resistance Measurements) ....................... 20
3.3. Measurements ................................................................................................ 23
3.4. Auto Hold / Record ................................................................................ 25
3.5. Judgment of Battery Condition ........................................................................ 27

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SBS-6500 User Manual
Storage Battery Systems, LLC.
4. Limit (Comparator) ........................................................................................... 28
4.1. Limit Judgment Function ................................................................................. 28
4.2. Limit Function Operation Procedure ............................................................... 29
4.3. Judgment of Limit ............................................................................................ 30
4.4. LIMIT Function – Audible Tones ..................................................................... 31
4.5. Release LIMIT Function .................................................................................. 31
5. Data ........................................................................................................ 32
6. Data - Data Base (DDBB) ....................................................................... 33
6.1. Data Base Entries ........................................................................................... 34
6.2. Data Base Functionality .................................................................................. 34
6.3. Entry and Deletion of DB Entries .................................................................... 34
7. Data – Recording Function .................................................................... 37
7.1. Record Function .............................................................................................. 38
7.2. Record Memory Matrix .................................................................................... 38
7.3. Record Display ................................................................................................ 39
7.4. String Set-Up .................................................................................................. 40
7.5. Recording Address Selection. ......................................................................... 42
7.6. A-REC (Auto Recording ) ................................................................................ 43
7.7. Review of Recorded Data ............................................................................... 44
7.8. Erase of Recorded Data.................................................................................. 45
7.9. How to Input Reference (Initial) Data .............................................................. 46
7.10. Copy and Paste of Recorded Data ................................................................. 48
8. Data- Table ............................................................................................. 49
8.1. Recall .............................................................................................................. 49
8.2. Table ............................................................................................................... 50

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SBS-6500 User Manual
Storage Battery Systems, LLC.
9. Data – Curve ......................................................................................... 52
9.1. Curve (Trend Curve Analysis) ......................................................................... 52
10. SBS-2003 Digital Hydrometer SG Upload ...................................................... 54
11. Auxiliary Functions .......................................................................................... 57
11.1. Auto Power Off ................................................................................................ 57
11.2. Low Battery Warning ....................................................................................... 58
11.3. Menu Mode ........................................................................................... 58
11.4. HELP ..................................................................................................... 61
12. SBS Battery Link Software .............................................................................. 62
12.1. Description ...................................................................................................... 62
12.2. Suggested Operation System ......................................................................... 62
12.3. Connection between the SBS-6500 and the PC ............................................. 62
12.4. SBS Battery Link - Software Installation Procedure ........................................ 63
12.5. Un-installation of the SBS Battery Link Software. ........................................... 65
12.6. Software Instructions ...................................................................................... 66
12.7. Exiting Software .............................................................................................. 75
13. Specifications ................................................................................................... 76
13.1. General Specifications .................................................................................... 76
13.2. Electrical Specifications .................................................................................. 78
13.3. Accessories ..................................................................................................... 79
14. Maintenance ..................................................................................................... 80
14.1. General Maintenance ...................................................................................... 80
14.2. Fuse Replacement .......................................................................................... 81
14.3. Battery Replacement ...................................................................................... 81

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SBS-6500 User Manual
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14.4. Troubleshooting .............................................................................................. 82
14.5. Test Probe Pin Replacement .......................................................................... 82
14.6. Cleaning .......................................................................................................... 83
14.7. Disposal .......................................................................................................... 83
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
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SBS-6500 User Manual
Storage Battery Systems, LLC.
Notes for Safe Operation
Please review the following items regarding safety in order to prevent damage to the SBS-
6500 Battery Resistance Tester or any connecting system. To prevent any potential harm,
operate the tester according to the instructions in the manual.
The SBS-6500 is designed and tested according to the International Safety Standard IEC
61010-1 before delivery.
Incorrect or improper measurement methods may cause personal injury or damage to the
tester.
[Safety Terms and Symbol]
Technical terms which appear in this manual are listed below.
Before using the tester, please read and follow all safety warnings carefully.
: WARNING
“WARNING” statements identify a condition or practice that could result in injury or loss of
life.
: CAUTION
“CAUTION” statements identify a condition or practices that could result in damage to the
SBS-6500 or other property.
: Users should read the marked areas of the manual and pay special
attention to the warnings prior to operating the tester.
: DC (direct current or voltage)
: Fuse
: Grounding terminal

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SBS-6500 User Manual
Storage Battery Systems, LLC.
Operation Environment
Temperature relative humidity range: 32 to 104 °F (0 to40℃), max 80%rh
(non- condensing)
Guaranteed accuracy temperature, relative humidity range
65to 85°F (23±5℃), max 80% rh (non-condensing)
Please do not expose the SBS-6500 for long periods of time to the following
environments which could damage or cause malfunctions/inaccuracies.
Prolonged exposure to direct sunlight
Extremely high temperature
Wet environments
High humidity and dew
Dusty environments
Explosive gases
Strong electromagnetic fields
Near sensitive electronic objects
Excessive vibration
Precautions before use:
Upon receipt, inspect the unit and test leads for any signs of physical damage. Notify
SBS prior to use of any defect or problem.
Check the test leads for signs of worn or broken insulation. Worn, abraded or damaged
leads should never be repaired. Broken leads should be replaced with new leads only.
To prevent electric shock, never use any feature of the tester with the covers open.
To prevent damaging the tester, avoid drops, falls and severe mechanical jolts.

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SBS-6500 User Manual
Storage Battery Systems, LLC.
 Precautions for Measurements
To prevent Electric Shock Hazard, please pay attention to the following precautions:
When measuring internal resistance (impedance), the battery voltage should not
exceed 100V DC. When measuring DC Voltages, Input voltage on test leads should not
exceed 300V DC.
Do not measure AC voltages. Unit is designed for DC voltage measurement only.
Proper polarity of battery test probes (for internal resistance, voltages), and proper
connection of the USB Cable (for PC communication).
Pay special attention to the possibility of a spark when connecting the test leads to the
battery. DO NOT TEST in hazardous locations with flammable or explosive gases
present.
Cautions for Test Probes
For safe and accurate measurements, use only the battery test probes supplied with the
SBS-6500.
To prevent failure of breaking wires, do not pull or fold the test probe cables.
Tips of test probes are sharp, use care to prevent injury.
Do not use excessive force which could damage the test probes.

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SBS-6500 User Manual
Storage Battery Systems, LLC.
1. Introduction
1.1. Battery Condition Determination
The SBS-6500 is designed to be your best tool for determining the state of health of your
battery systems or cells and tracking that history over the entire life of the system s. As
batteries age, internal resistance values change in proportion to the condition of the
batteries performance capabilities. A rapid increase in internal resistance can indicate a
failure is eminent in the near future.
In general, the internal resistance value of a cell or battery will increase by 1.5 to 2 times
from the initial value (reference value) when the battery is deteriorating. Regular
measurements for comparison will provide warning to take corrective actions prior to its
actual failure.
[Judgment of Health (Deterioration)]
Lead acid storage batteries are common in that they all undergo the same type of plate
deterioration over the life span of the battery. This comes in the form of plate
structural losses and material corrosions which increase the resistance inside the cell.
Batteries of the same capacity may have very different initial internal resistance values
due to the design, construction and physical number and size of the plates.
Comparisons should only be made against that manufacturer’s published values or the
original installation values for the system.
The “warning” and “fail” values of batteries from different manufacturers is the same
however, it is a percentage change over the life of the battery as it ages.
[Recommendations for Maintenance Activities]
IEEE recommendations and NERC/FERC requirements call for periodic maintenance
activities which measure and record this data, as well as cell voltages and temperatures to
allow for tracking, charting and analysis of the data to determine how soon system or cell
replacement will be required.
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
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SBS-6500 User Manual
Storage Battery Systems, LLC.
[Determination of Battery Replacement Time]
Based on the specifications of the battery, projected life and actual service life, the
trending and graphing of test results can indicate how quickly a battery or battery
system should be replaced.
Proper timing of replacements for failing cells or systems can eliminate an unsuspected
or catastrophic, costly failure from occurring. This type of maintenance and data tool
allows for pre-planned, budgeted replacement of battery systems before it becomes a
matter of urgency.
1.2. Description
The SBS-6500 was designed for measuring the internal resistance, voltage and
temperature of batteries across all applications and types including lead acid cells,
nickel-cadmium batteries, lithium–ion batteries and nickel-metal hydride batteries.
Measurement data is stored in a 7.5 million data record memory and is transmitted via
a USB connection to a PC for printing of reports, graphs and exportation of the data
into Excel.
The unit includes a 200 record programmable reference library of battery reference
values for comparison and pass/warning/fail indication at time of testing.
SBS-6500

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SBS-6500 User Manual
Storage Battery Systems, LLC.
1.3. Special Features
On-Line NON-Destructive Test of Battery Conditions
Using the newest advances in technology, the SBS-6500 measures the data of battery cells
and provides a conditional comparison which can be used to determine a batteries current
state of health and records data for trend comparisons for the life of the battery string .
Method of measurement does not collapse float voltage or discharge the battery to
accomplish measurements.
Accurate Measurement
AC signal, four-terminal method of measuring the internal resistance. Eliminates lead
resistance and contact resistance to achieve the most accurate results.
 Internal Resistance, Voltage, Temperature Measurements (Simultaneously)
Optional accessories allow for importing specific gravity readings from the SBS-2003
Digital Hydrometer. V/A measurement mode allows unit to be used as a digital multimeter
as well as an IR tester.
Comparator
Up to 200 sets of reference battery values can be entered in the comparison database.
Reference value selection allows for reliable comparison of current readings and the LCD
displays pass, warning and fail results and an audible alert for warning and fail results.
[PC interface]

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SBS-6500 User Manual
Storage Battery Systems, LLC.
SD High Capacity Memory
All measurement data (7,530,000 data blocks) including resistance, voltage, temperature,
currents, comparator result and specific gravity (data upload from SBS-2003 gravity tester
via Bluetooth) can be saved in the internal SD memory of the SBS-6500. This capacity
allows a history archive of:
String
(Bank)
Max 301 (including 1 auto string )
No: 000 - Reference DB not registered and open default string
No: 001 - 300: Reference DB comparison registered
Cells
Max 250 cells per string
Test
100 measurements for each cell/battery over its life.
Auto Saving
In AUTO REC the measurement data is automatically saved in the internal memory.
Maximum of 250 cells’ data can be saved in order. The saved data can be transferred to
any assigned address in the string record memory or can be removed.
PC Interface - Functional Control through PC
Any of the data stored in the internal memory of the SBS-6500 can be reviewed on the
hand held unit directly via the data menu or by connecting the unit to the PC with the
supplied USB cable and using the SBS Battery Link Software. All data in the memory can
be reviewed, printed or exported via the software interface that comes with the unit. The
software also allows direct input of string set-up and programming of the Reference DB
while the SBS-6500 is connected to the software.
Back up and restoration of the entire memory is available under the FILE tab in the
software. It is recommended that the SBS-6500 memory is backed up after initial
programming of the unit, after maintenance activities are completed and prior to sending
the unit in for calibration, evaluation or repairs.
The functional controls of the SBS-6500 are mimicked on the software allowing for
selection, entry and saving of programming features.

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SBS-6500 User Manual
Storage Battery Systems, LLC.
1.4 Description of each part and functions
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
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SBS-6500 User Manual
Storage Battery Systems, LLC.
①Impedance, volt input: Connect plug of the RED test probe.
②Impedance, volt, temperature input: Connect plug of the BLACK test probe.
③LCD display.
④HELP
⑤Power : Power ON/OFF
⑥LCD back light
⑦Auto/manual ranging
⑧Up/down/left/right direction function
⑨Menu key (F1~F4)
⑩Impedance (internal resistance) key
⑪Data (DB, record, table, curve) key
⑫SBS-2003 upload key
⑬V / A key
Volt: max DC 300V input. Currents: adapter DC 40A/400A.
⑭Menu key
⑮Auto record on/off key
⑯Encoder rotary switch:
Turn clockwise or counterclockwise direction to select the displayed selection items
and push down the selected item to set.
⑰DCA input jack
Indirectly connects with DCA current adaptor (for 40A/400A ).
⑱USB interface: PC interface connector.
⑲AC adaptor input jack: Connects to the AC power adapter

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SBS-6500 User Manual
Storage Battery Systems, LLC.
[Display]
①Present measurement value in auto record mode
(When measurement in auto hold mode, auto hold data “0.995”is holding at center of display
and present measurement data shows “0.997”. This data box does not appear if auto hold mode
is inactive.)
②Measurement date and time
③Battery state of charge/AC adapter indication
④Limit: upper2, upper1, and low voltage warning reference points.
⑤Impedance value display
⑥Unit of measurement
⑦Temperature value display
⑧4m Ωrange key
⑨String-Cell-Test display (REC No: )
⑩Measurement average and number of averaged data
(Displayed in conjunction with auto hold)
⑪Comparator (pass –warning-fail) indication.

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SBS-6500 User Manual
Storage Battery Systems, LLC.
⑫Auto record: When in auto hold, auto record is automatically activated. Readings
are saved at the preselected record memory address in order, max of 250 cells.
⑬Auto: auto, manual ranging
⑭Warning sign (safety ratings limits exceeded)
⑮DC voltage measurement
1.5. Dimensions and Weight
Dimensions: 4.2” (W) x 8.3” (H) x 2.2” (D) / 107 ㎜(W) x 220㎜(H) x 55㎜(D)
Weight (main unit including battery ) : 2.2 lbs / 1.0㎏

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SBS-6500 User Manual
Storage Battery Systems, LLC.
2. Initial Settings Before Use
2.1. Insert Test Leads
To avoid measurement errors or electrical shock, make sure to insert the test leads into the
tester correctly according to the marked polarity. Jacks are pinned to prevent cross
connection.
For safe and accurate measurement of resistance and voltage, only use the battery test
leads supplied with the SBS-6500. Replacement test lead sets are available.
Insert the SCK type plug of test leads into (+) and (-) as shown in the picture below.
Clamp type battery test leads are an optional accessory available.
Part Number: 6500-CLAMP-PROBE
[Insert SCK type plug]
[Pin type battery test lead for
impedance, voltage,temperature measurement]
99 Washington Street
Melrose, MA 02176
Phone [phone]
Toll Free 1-800-517-8431
Visit us at www.TestEquipmentDepot.com

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SBS-6500 User Manual
Storage Battery Systems, LLC.
Besides measurements for resistance, voltages and temperature, a clamp type high
current adapter can be used for indirect measurement of DC Currents in the V/A mode
of the SBS-6500.
DC hi current adapter (CT) for indirect measurement: 40A/400A DC range.
DC current adapter is an optional accessory.
Part Number: 6500-CURRENT-CLAMP
2.2. Power ON/OFF
Use the power key on the unit to power the SBS-6500 on or off.
[ON]
Hold the power key longer than two seconds. The unit will power on with a beep sound.
After power on, initial display on screen shows manufacturer and firm ware version
information momentarily and then changes to measurement function in auto record
mode of operation.
[OFF]
Hold the power key longer than two seconds. The SBS-6500 will power off with beep
sound.
2.3. Real Time Clock function
Once the date and time are set, the unit features real time clock stamping. The upper line
of the LCD screen displays: month/day/year (left) and hour/minute/second (right).
Press the key to enter the Menu mode. Select YY/MM/DD or
MM/DD/YY.
If the time is not correct, select and to adjust time.
Set day, month, year, hour, minute, seconds and then press key to save
time settings.

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SBS-6500 User Manual
Storage Battery Systems, LLC.
2.4. Back Light Display
Press key will toggle the LCD back light on or off.
2.5. String and Reference Set-Up
Follow the (SBS-6500 String and Reference Set-Up Guide) supplied on the disk
with the software for setting up all of your battery string locations, entering all of
your battery types and setting alarm reference settings.

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SBS-6500 User Manual
Storage Battery Systems, LLC.
3. Measurement
For safe and accurate measurements, please read the full manual carefully.
Make sure to pay attention to the following:
Do not measure over DC 100Vbattery at impedance measurement range. This
is to protect from electric shock.
Do not measure over DC 300V input when measure voltage at is measurement
range. This is to protect from electric shock.
Do not measure AC voltages in either testing mode of the unit.
[Caution]
Do not exceed the maximum rated voltage or current of each measuring range.
Exceeding input ratings may cause damage to the tester.
[Note]
Internal resistance of the battery being measured can be done with the system
charging or on open circuit. Low voltage limits should be adjusted to the condition of
the battery at the time the measurements are being made.
In order to increase accuracy of measurements from one inspection to the next, the
measurements should always be taken in the same location. Measurement of batteries
directly on the posts will provide more accurate readings. Hardware, washers and lugs
all add resistance to the measurement values.
Ensure the probe pins are clean and free of dirt, dust, etc. prior to taking
measurements.
3.1. “0” Point Adjustment before Measurement
Zeroing out the test leads prior to use ensures that the resistance of the leads
themselves is not included in the measurements being taken.
“0”adjustment is required when the unit is first set-up, when switching from one set of
test leads to another and periodically to ensure accuracy of readings.
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
TestEquipmentDepot.com