SBS 8400 User manual

SBS-8400
BATTERY CAPACITY TESTER
USER MANUAL
Rev. 2.1 12-14
STORAGE BATTERY SYSTEMS, LLC
N56W16665 Ridgewood Dr., Menomonee Falls WI 53051
Phone: [phone] Fax: [phone] Website: www.sbsbattery.com

SBS-8400 USER MANUAL
Contents
1. Introduction
1.1 Features
1.2 System Components
2. Main Technical Parameter
2.1 Environment & Conditions for Use
2.2 Structure & Weight
2.3 Working Power Supply
2.4 Input Voltage from Battery strings
2.5 Discharge Current Range
2.6 Parameter Display & Measure Accuracy
2.7 Protection & Warning
2.8 Data Management & Communication
3. Basic Operational Principle
3.1 Battery Testing Principle
3.2 Constant Current Principle
4. Operating Instructions
4.1 Environments Requirement
4.2 Panel Description
4.3 Main Machine Connection
4.4 Wireless Modules Connection
4.5 Starting Up and Input Operation
4.6 Check the Connection of the Wireless Modules
4.7 The Preset Function
4.8 Discharge
4.9 Download the Data to PC
4.10 System Setup
4.10.7 Calibration
4.11 Charge Monitoring Function
4.12 Multiple units in parallel
5. PC Software Instruction
5.1 Main Functions
5.2 Install Analysis Software to PC
5.3 Real Time Recording During the Testing
5.4 Download Data File from USB Disk
5.5 Generate Excel Test Report
6. Precautions
7. After-Sale Service

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1. Introduction
Battery-based backup systems have become an ever-increasing source of providing
emergency power to critical systems and components. Maintaining these systems
and knowing that they will be able to perform when called upon in an emergency
has led to an increasing demand for testing methods to guarantee reliable operation.
In addition, new requirements and recommendations (FERC, NERC, IEEE, etc...) are
requiring more stringent attention to the reliability and performance of batteries
used in these critical applications.
As we know, there are many factors which determine the actual service life that a
battery string will reliably perform before failures or reduction in capacity requires
replacement. While period maintenance and routine monitoring of measurements
gives you some idea of a battery’s condition, it is only by actually testing the capacity
of the battery string that you know what its capabilities are and how close it is to its
end of useful service life.
With these ideas in mind, SBS has developed the SBS-8400 as an advanced, highly
accurate and intellectual testing system for conducting load testing of battery strings.
With innovative features, such as wireless data collection, real time monitoring, and
integrated software, the SBS-8400 is the tool of choice for consistent, reliable and
affordable battery capacity testing.
Advantages of the SBS-8400:
a) Wireless battery monitoring technology - Available for 1.2V/2V/6V/12V cells
voltage monitoring.
b) Each wireless module can monitor 4 cells simultaneously - Compared with
traditional methods where each module can only monitor 1 cell, the new
module design requires only a quarter of the number of old-fashioned modules.
(Only 6 wireless modules for 48V battery strings.)
c) Parallel monitoring of multiple battery strings - The SBS-8400 can
simultaneously record the actual discharge currents and voltages of each battery
strings under test. (Accessories, extra current clamps are needed for multi-string
testing.)
d) Automated constant current control during on-line tests - During the discharge,
the current displayed in the LCD = the discharge current of battery string. The
SBS-8400 is capable of monitoring the current created by the main machine +
the current of the actual load. This allows for testing the battery system and
automatic adjustment based on the system real and artificial load.
e) Selectable number of low voltage limits - This feature allows the test to
continue instead of stopping as soon as the first cell reaches the low cell voltage
setting and allows for testing to continue after a weak / bad cell is jumped out of
the string.

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f) Simplified menu design - The simplified menu allows for easy test set up and
operation.
g) Light weight alloy heat sink elements - New generation materials increase safety
and thermal transfer of heat to air.
h) Auto scan and display of the voltage data for each battery during the discharge
Graphical histograms display the status of each cell throughout the discharge,
and the use of different colors to highlight the lowest and the highest voltage
can simplify the identification of possible problems.
i) 5.7 inch colorful touching LCD screen - The large touchscreen allows menu
selection and programming, and shows all parameters and the voltage histogram
during the discharging process.
j) Intelligent judgment program - SBS-8400 continuously monitors voltages and
regulates test progress to shutdown parameters. Automatic adjustment of
discharge current level allows this revolutionary program to keep the test stable
and smooth.
k) Presetting function for discharge parameters - SBS-8400 provides 30 presets for
setting up discharge parameters in advance; this design can simplify the
programming operation and speed up testing.
l) Real Time PC Logging- Powerful software for downloading real time data, or use
the USB port to download the data after the discharging process. PC analysis
software assists users in analysis of the data and creation of test reports.
m) 8M internal memory - SBS-8400’s internal memory can record several sets of
test result data independently and the menu interface provides basic
management operations like reviewing, analyzing or deleting test results.
The Advantages / Features of SBS-8400 Analysis Software:
a) Allows data downloading and analysis through real time communications or USB
memory device downloads.
b) The software interface includes: battery/cell voltages curves and bar charts,
group voltage curve, current curve, capacities histogram and a raw data matrix.
c) Powerful capacity calculating function - the software calculates the capacity of
each battery in the tested group.
d) The software shows the data in various forms such as bar charts, curves, and
table formats. Users can magnify or minimize any windows to view more details.
e) Automatically creates EXCEL data reports; convenient to send or download the
data.
SBS-8400 has multiple protective functions, which include the audible alarms,
warning lights and clear interface prompts.
SBS-8400 is a compact, lightweight, simple to operate and highly accurate testing
platform. SBS-8400 is versatile in its ability to discharge test 12V, 24V, 48V, 72V, 96V,
110V, 120V, 220V, 240V battery strings etc., across many applications.

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1.2 System Components
The SBS-8400 battery capacity tester includes the main machine, wireless modules
for cells monitoring (optional), wireless signal receiver and PC analysis software.
The main unit consists of a color LCD screen, data processing unit, data monitoring
unit, auxiliary power unit, power consumption unit and panel operation unit.
2. Technical Parameters
2.1 Environment & Conditions for Use
2.1.1 Operating temperature:
20°F ~ 122°F (-5℃~ +50℃), full power, forced air cooling
2.1.2 Storage temperature:
-40°F ~ 150°F (-40℃~ +70℃)
2.1.3 Relative humidity:
≤90% 105°F±5°F (40℃±2℃)
2.1.4 Altitude limit:
0~2000m, 20°F ~ 122°F (-5℃~+50℃), full power
2000m～4000m, 20°F ~ 90°F (-5℃~+30℃), full power;
90°F ~ 122°F (30℃~+50℃), 80% of ratings.
2.2 Structure & Weight
Dimensions: (length*width*height):
SBS-8400: 26.4” x 9.05” x 14.6” (670mm x 230mm x 370mm)
SBS-8400 Battery
discharge &
capacity tester
main machine
color LCD screen
data processing unit
data monitoring unit
auxiliary power unit
power consumption
unit
panel operation unit
wireless modules for
cells monitoring
PC analysis software
wireless signal
receiver

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Weight:
SBS-8400: 52.9 lbs. (24 kg) {main tester only}
2.3 Working Power Supply
SBS-8400:AC 120V single phase 45Hz~65Hz (220VAC optional)
2.4 Input Voltage from Battery String
SBS-8400: 10 ~ 300V
2.5 Discharge Current Range
Voltage range
Current range
10-15V
0-60 A
15V-60V
0-120 A
86-150V
0-120 A
190-280V
0-60 A
2.6 Display & Measurement Accuracy
LCD Display: 5.7 inch LCD color touch screen
Displayed discharge current: resolution 0.1A
accuracy≤±0.5%
Displayed battery strings voltage: resolution 0.1V
accuracy≤±0.5%
Displayed cells voltage: 1.2V/2V/6V cells resolution 0.001V
accuracy≤±0.05%
12V cells resolution 0.01V
accuracy≤±0.05%
2.7 Protection & Warning
Protection features of the SBS-8400:
2.7.1 DC input overvoltage, polarity reversal at battery connection, DC over current
during discharge, and system over temperature.
2.7.2 Warning light and audible alert will activate, and the LCD screen will show
message / prompt.
2.8 Data Management & Communication
2.8.1 Discharge data management
a) Data sampling is saved continuously and automatically, so test records are not
lost even due to a loss of power.
b) Allows for manual review of data.
c) Allows for reading & downloading data via the communication port.
d) Displays the remaining capacity of the internal memory.
e) Smart delete selection: delete all or delete the selected record from memory.

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2.8.2 Preset Test Parameters
The “Preset” interface allows the user to program and store in the internal memory
of the SBS-8400 up to 30 test preset parameters for quick selection and setup.
2.8.3 Communication
a) Internal wireless signal receiver allows the SBS-8400 main unit to record the cell
monitoring & sampling data.
b) Via the RS232 port in SBS-8400 main unit, a PC can be connected to display real
time discharge data.
c) Via the USB port in SBS-8400 main unit, test result data can be transferred to a
PC by a USB-disk.
d) Via the Parallel control port, SBS-8400 main unit can control a SBS-S series DC
load bank.
3. Basic Operational Principles
3.1 Battery Testing Principle
Because of the differences in materials, construction, craftsmanship, installation
environments, and maintenance practices, battery strings from different
manufacturers have many unique characteristics. Even the same types of batteries
from the same manufacturers will see variances in performance and capacity from
one string to another. There are many ways to predict the condition of a battery
systems performance and remaining life expectancy, however, the IEEE capacity
testing procedures are the only definitive proof of a battery systems ability to
perform as specified by the battery manufacturer.
Nowadays, with the popularity of VRLA batteries, fewer indications are available to
determine the condition of a battery.
We believe:
a) The battery voltage in float charge operation and the batteries true capacity
have no direct correlation.
As we know, batteries which have a low capacity can still display a normal voltage in
float mode. Simple interpretation of available data is not accurate in determining if a
battery will perform as required when called upon.
b) Full rated capacity discharging is still the most accurate method to test the
performance of batteries.
For systems which are created by a number of cells connected in series, the actual
capacity of battery string relies on the ability of the worst cell to perform to capacity.
The principle goal of capacity testing is to find these poorly-performing cells and
replace them to increase the service life and reliability of the whole battery system.
Applying a constant current as specified by the manufacturer for a specific period of
time allows for monitoring the batteries’voltage to ensure the cell remains above

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the specified cut off voltage and allows us to determine the battery and systems
actual performance capacity as a way of ensuring the systems’performance.
Examining a voltage drop curve for the discharge rates:
From the curves, we know what the performance is supposed to be at a given rate of
discharge and this is the most uniform and accurate method for estimating the
capacity of a battery.
3.2 Constant Current Principle
The internal circuitry of the SBS-8400 uses a PWM (pulse width modulation) control
technique. Controlled by the CPU and sensing circuits, the power circuit can
discharge the battery string with very accurate, automatically corrected control.
Data collection and interpretation by the software is automatic and accurate.

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4. Operating Instructions
4.1 Environment Requirement
The unit should only be used in environments that are free from dust and flammable
or explosive gases. It should be properly ventilated to dissipate heat produced.
4.2 Panel Description
Main machine
Wireless module for 2V/6V/12V—SBS-2612
Antenna
LCD screen
Wired modules
input
Parallel input
RS232 port
USB port
DC breaker
Cable socket
AC input socket
Power switch
Power light (green)
Communication light
(red)
Alligator clip
(4 yellow, 1 red, 1 black)
External
current
measurement
Air cooling fans

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4.3 Main Machine Connections
4.3.1 Use the power cables (1 red, 1 black) to connect the SBS-8400 to the battery
string to be tested.
4.3.2 Use the power supply cord to provide the SBS-8400 with an AC power source.
a) The SBS-8400 supports 120V AC 50Hz/60Hz external AC input power.
b) If your power source is 220V AC 50Hz/60Hz, please use the optional 220V AC to
110V AC transformer to power the unit, or inform us when you plan to order a
SBS-8400 and unit will be shipped to support 220V AC.
120V AC 60Hz
Power Source
220V AC 50Hz
Power Source
(Optional)
Power supply cord
Power Cable (red)
Power Cable (black)
Battery String
DC Breaker
Wireless module for 1.2V/2V-SBS-12612
Power light (green)
Communication light
(red)
Alligator clip
(4 red, 1 black)

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4.4 Wireless Modules Connections
Before connecting the wireless modules, please install the antenna.
4.4.1 SBS-2612 wireless modules (for 2V) connections
4.4.1.1 Reading the module number from the modules’ labels, find the correct cells
to connect the module to. Do not connect the modules to 4 batteries which are not
in series like No. 1, 5, 8, 9 - misconnection will likely damage the module
immediately!
4.4.1.2 Use the alligator clips (1 red, 1 black, 4 yellow) to connect modules to the
batteries. Please follow the correct wiring rule “Yellow 1 to Yellow 4, from long to
short. A wiring diagram is printed on the label of the modules for your reference.
SBS-2/6/12 Wireless Module
Wireless module number and the battery to connect
For example: NO.1 module -- Connect to cells NO.1-NO.4 (from positive)
NO.2 module -- Connect to cells NO.5-NO.8 (from positive)
NO.3 module -- Connect to cells NO.9-NO.12 (from positive )
………..
Cell
NO.1
Cell
NO.2
Cell
NO.3
Cell
NO.4
NO. 1 Wireless module
Red
Yellow 1
Black
Cell
NO.5
Cell
NO.6
Cell
NO.7
Cell
NO.8
NO. 2 Wireless module
Cell
NO.4K+1
Cell
NO.4K+2
Cell
NO.4K+3
Cell
NO.4K+4
NO. K Wireless module
Yellow 2
Yellow 3
Yellow 4
Wiring Diagram

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4.4.2SBS-2612 wireless modules (for 12V, 6V) connection
4.4.2. Read the module number from the label the modules, find the correct cells to
connect the module to. Do not connect the modules to 4 batteries which are not in
series like NO.1,5,8,9, misconnection will likely damage the module immediately!
4.4.2.1 Use the alligator clips (1 red, 1 black, 4 yellow) to connect modules to the
batteries, please follow the correct wiring rule “Yellow 1 to Yellow 4, from long to
short”, and the wiring diagram also print on the label of the modules.
SBS-2/6/12 Wireless Module
Wireless module number and the battery to connect
For example: NO.1 module -- Connect to batteries NO.1-NO.4 (from positive)
NO.2 module -- Connect to batteries NO.5-NO.8 (from positive)
NO.3 module -- Connect to batteries NO.9-NO.12 (from positive)
………..
Cell
NO.1
Cell
NO.2
Cell
NO.3
Cell
NO.4
NO. 1 Wireless module
Yellow 1
Black
Cell
NO.5
Cell
NO.6
Cell
NO.7
Cell
NO.8
NO. 2 Wireless module
Cell
NO.4K+1
Cell
NO.4K+2
Cell
NO.4K+3
Cell
NO.4K+4
NO. K Wireless module
Yellow 2
Yellow 3
Yellow 4
Wiring Diagram
Red

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4.4.3 SBS-1.2/2 wireless modules (for 1.2V, 2V) connection
4.4.3.1 Read the module number from the label the modules, find the correct cells to
connect the module to. Do not connect the modules to 4 batteries which are not in
series like NO. 1, 5, 8, 9 –the misconnection will likely damage the module
immediately!
4.4.3.2 Use the alligator clips (4 red, 1 black) to connect modules to the batteries,
please follow the correct wiring rule “Red 1 to Red 4, from long to short”, and the
wiring diagram printed on the label of the modules.
4.4.4 Connection guide when cell quantity is not a multiple of 4
4.4.4.1 SBS-2/6/12 wiring for last 4 to 1 cells
SBS-1.2/2 Wireless module
Wiring Diagram
Wireless module number and the battery to connect
For example: NO.1 module -- Connect to cells NO.1-NO.4 (from positive)
NO.2 module -- Connect to cells NO.5-NO.8 (from positive)
NO.3 module -- Connect to cells NO.9-NO.12 (from positive)
………..
Cell
NO.1
Cell
NO.2
Cell
NO.3
Cell
NO.4
NO. 1 Wireless module
Red 1
Red 2
Red 3
Red 4
Black
Cell
NO.5
Cell
NO.6
Cell
NO.7
Cell
NO.8
NO. 2 Wireless module
Cell
NO.4K+1
Cell
NO.4K+2
Cell
NO.4K+3
Cell
NO.4K+4
NO. K Wireless module

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4 yellow wires, from left to right = from long to short
means this wire is not connected
|separates the groups of cells
Last four 2V cell
Last four 6V/12V cell
Last three 2V cell
Last three 6V/12V cell
Last two 2V cell
Last two 6V/12V cell
Last one 2V cell
Last one 6V/12V cell
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module

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4.4.4.2 SBS-1.2/2 wiring for last 4 to 1 cells
4 red wires, from left to right = from long to short
means this wire no need to connect
separate the last cells with other cells
Last four 1.2V/2V cell
Last three 1.2V/2V cell
Last two 1.2V/2V cell
Last one 1.2V/2V cell
4.4.5Spare modules and reassigning module numbers
4.4.5.1 No. 0 spare modules
With each module set you will find No. 0 spare modules. They
have the following label: No number assigned. They can be
addressed to any module No., and allow testing to continue if
any assigned module should fail.
4.4.5.2 To Activate a No. 0 spare module:
When any assigned module fails (for example, No.
3 module), you can connect one of the spare
No. 0 Spare module label
Module
Module
Module
Module
Module
Module
Module
Module

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Power switch
modules to 4 cells, just like a normal module. Disconnect all other modules.
Re-address the spare module to No. 3 to replace the failed one by entering the
‘Config Module Addr:’ of the 'Setup' menu. Set '003#' and press 'config'. The spare
module will become the new No. 3 module.
4.4.5.3 How to Erase and Reassign the Assigned Modules (Numbered)
If you run out of spare modules, and one of the assigned modules fails (for example,
No. 3 module fails) you can erase No.15 and reassign to No. 3 for this urgent
requirement.
a) Open the No. 15 module box; you will see a
small button on the PCB. (Yellow frame in the
picture.)
b) While holding this button down continuously,
connect it with 4 cells, just like you would a
normal module. It will power on, and then wait
10 seconds. Release the button.
c) Check 'BatteryView' in LCD, if Cells 57- 60
(normally on No. 15 module) have no data, it
means No. 15 module has been reset to a No.
0 spare one.
d) Follow the procedure in '4.4.5.2 To Activate a No. 0 spare module', to edit it to
No. 3.
4.5 Starting Up and Input Operation
4.5.1 After the SBS-8400 has been connected to the battery
system, turn on the “AC” power switch.
4.5.2 A welcome interface will appear where you can see the unit
identification. Press anywhere on the screen to go to the main menu. If 10
seconds elapse, the system will jump to the main menu automatically.

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The Welcome Screen
The Main Menu
Table
Chart
4.5.3 SBS-8400 input method: touchpad directly on LCD screen.
4.6 Check the Connection of the Wireless Modules
4.6.1 Press “BatteryView”on the main menu to enter the table interface, if all
wireless modules are connected correctly, you will see the voltage of each cell. If the
voltages of some cells are not showing, please re-check the wireless module
connections.
4.6.2 Press “Chart”to see the histogram for each cell in the string.
Back to the main menu
Each screen can show 24 cells.
For more than 24 cells, press “Next”
“Prev”to see the other pages.
The highest & lowest voltage
cell in battery string

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Preset
4.6.3 Both the table and chart interfaces show 24 cells at a time. If the tested battery
string has more than 24 cells, press the “Next”& “Prev”to see the other cells.
4.6.4 Press “Exit”to go back to the main menu
4.7 The Preset Function
4.7.1 The preset function allows 30 programmable locations to save discharge test
setups. You can select any of the preset tests and press “Apply”to use those
discharge parameters. The SBS-8400 supports manual setting in the discharge
interface without using the preset features.
Press “Preset”on the main menu to enter the preset interface
4.7.2 “TestCapa”, “TestTime”, “BattLowV”, “GrpLowV”are the test stop conditions, if
any of these set-points is reached, the discharge will stop automatically.
4.7.3 For 1 battery string discharge, please keep “#Strings”at “001G”; if parallel
discharging 2-4 strings is needed, 2-4 times the wireless modules will be needed. The
discharge current will be ½ - ¼ for each string being tested.
4.7.4 If you want the discharge to stop when one bad cell reaches the “BattLowV”,
please keep “#Battlow”in “001#”. If you want the discharging to stop when N bad
cells reach the “BattLowV”, you can set the “#BattLow”to the number you need.
4.7.5 If you are not utilizing the wireless modules for the discharge, please set the
“BattSum”to “000#”. “BattLowV”will be disabled from terminating the discharge.
Preset parameter number
AhRate: The rated capacity of
the tested battery string
HourRate: The hour rate of
discharge
SaveTime: the time interval
of the data recording
PowerSet: discharge power (if
using CKW mode)
TestMode:
CCurrent (constant current)
CKW (constant power)
ACError: the reaction for AC
power losing, for SBS-8400,
This item will lock at ‘Stop’
#Strings: number of strings in
parallel being tested at once
TestTime: the discharge time
TestCurr: discharge current (if
choose CCurrent Mode)
BattSum: cell qty in battery
string
GrpLowV: the lower limit
voltage of battery string
Press “Modify”to locate the preset parameters
need to be changed, “+”, “-”to change value,
“Cancel”to quit. After all setting, press “Apply”
to save
Recover all parameters
to default values
To change Parameter number
Param 1, Param 2, Param 3…..
TestCapa: the capacity need
to be discharged
BattLowV: the lower limit
voltage of cells
#BattLow: qty of cells which
voltages below “BattLowV”

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F0 & F1 Breaker
Parameter
4.8 Discharge
4.8.1 Press “Discharge”on the main menu to enter the discharge parameter
interface.
4.8.2 In the parameter interface, you will see all the same parameters as in the
“Preset”; you can re-edit the discharge parameters here and press “Apply”to save
them.
4.8.3 Press “Start”on the discharge interface,
and turn on the ‘F0’ breaker, if the battery string is
connected correctly to the unit by power cables,
you will see battery string voltage in ‘GroupVolt’.
4.8.4 Press “Start” again to start the discharge;
LCD will show a Popup-window to ask you to verify
if all fans are working. Then a popup-window again
will ask you to turn on the ‘F1’ breaker. The test will begin automatically as soon as
‘F1’ is closed.
4.8.5Manual stop the discharge: press “Pause”to pause the discharge, and press
“Stop”to end the discharge, or press “Start”to continue the discharge.
Press “Modify”to locate the preset parameters
needed to be changed, “+”, “-”to change value,
“Cancel”to quit. After desired values are
entered, press “Apply”to save, and the desired
changes will be updated to “Preset”
Back to the main menu
When the discharging starts, you can see the status in this
screen, it includes:
GroupVolt: the voltage of battery group
Current: the discharge current
TotalPower: the discharge power
CapaSum: the total capacity discharged
TestTime: the time since the discharge started
#BattLow: the quantity of the batteries in which voltage is
already below the “BattLowV” you set
MaxBatt(V): the highest voltage battery in the group
MinBatt(V): the lowest voltage battery in the group
To browse all cells’ voltages,
“Table” & “Chart”screens
are similar with the one in
“BatteryView”
Change the parameters in the
process of discharging; all changes
can be activated immediately!

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Data
4.8.6Press “Param”to adjust the parameters during the discharge (if necessary); all
changes can be activated immediately and the discharge will not be stopped.
4.8.7“SysState:”in the discharge interface will help you know the status of the
discharge.
4.9 Download Data to PC
4.9.1 SBS-8400 provides two methods to record the test data:
a) Use the RS232 cable to connect the unit with the PC. Through the analysis
software real time test data can be displayed and downloaded during the test.
b) Internal memory always saves all testing data; you can download the data via USB
disk or RS232 cable to a PC.
4.9.2 Press “Data”in the main menu to enter the data interface
The used percentage of internal
memory, if this value is low please
delete some old data
The information of the data file
Test time
& date
Delete the selected file
Delete all data files
If the data files are more than 1
page, use “Up”/ “Down” to browse
Plug USB into the USB port
Highlight the file to download and
press “USB”
Back to the main menu
Use RS232 cable to connect main
machine RS232 port with a PC
Select the file to download from
the software interface on the PC