SBS SBS-4815CT User manual
SBS-4815CT USER MANUAL
Contents
1. Introduction
1.1 Features
1.2 System Component Unit
2. Main Technical Parameter
2.1 Environment & Condition 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
4.11 Calibration
4.12 Charge Monitoring Function
4.13 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. Attentions
7. After-Sale Service
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1. Introduction
1.1 Features
The advantageous features of SBS-4815CT Battery Capacity Tester:
a) Adopting wireless battery monitoring technology: Available for 1.2V/2V/6V/12V
battery voltage monitoring
b) Each wireless module can monitor 4 batteries simultaneously: Compared with
the traditional method of each module only monitoring 1 cell, the new wiring
operation becomes easier because the quantity of new modules needed is only a
quarter of old-fashioned modules (only 6 wireless modules for 48V battery
strings)
c) Available for offline & online discharging tests of multiple battery strings, the
SBS-4815CT can simultaneously record the actual discharge currents of each
battery strings in the test. (As far as accessories, extra current clamps are needed
for multiple groups testing).
d) The discharge current is continuously adjustable and automatically keeps
stable, during the online discharging. The current displayed in LCD equals the
discharge current of battery string equals the current created by main machine
plus the current of the actual load. Because during the discharging the current of
the actual load probably changes according to the decrease of the online voltage,
SBS-4815CT can automatically adjust to keep the current stable in the entire test.
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.
f) Intelligent menu design, the simplified menu minimizes the training for users.
g) Applying the electric heating component made by aero-alloy for the power
consumption section, new generation material levels up the coefficient of safety
and the transition rate between electricity and heat, meanwhile reducing the
volume and weight. Light weight alloy heat sink elements –the new generation
materials increase safety and thermal transfer of heat to air.
h) Automatic calculating function for the discharging current, SBS-4815CT installs
the discharge current formula for all hour rates internally, so the setting interface
can tell you the suitable discharge currents without manual calculation according
to the marked capacities of battery strings and the testing hour rates.
i) Real scan and display of the voltage data for each battery during the discharge.
Display of the histogram of all batteries to follow the battery voltage tracks in
entire discharging process, using the different colors to highlight the lowest and
the highest voltage, which can simplify the analysis of the battery voltages.
j) 5.7 inch colorful touching LCD screen can fulfill the click operation on the screen
easily and directly, and show all parameters and the voltage histogram in the
discharging process.
k) Intelligent judge program, SBS-4815CT can identify when battery voltages reach
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the threshold value or a signal missing by manual mistake. Avoiding manual
interruption during the discharge, this revolutionary program makes the test
stable and smooth.
l) The presetting function for discharge parameters, the SBS-4815CT provides 8
locations for setting up all discharge parameters in advance. This design allows
you to skip the setting procedures for the same discharging and simplifies the
operation..
m) Connects with PC during the discharge for downloading of the real time data.
You are also able to use the USB memory device to download the integral data
after the discharging process. The PC analysis software assists users to analyze
the data and create test report.
n) With an 8M internal memory, the SBS-4815CT can record several sets of data
independently. The menu interface provides some management operations like
reviewing, analyzing and deleting.
The advantageous features of SBS-4815CT analysis software:
a) Support data downloading and analyzing through real time communication or
USB memory devices
b) The software interface includes: battery voltages curve and bar chart, battery
resistances bar chart, group voltage curve, current curve, capacities histogram,
data form and so on.
c) Powerful capacity estimating function, the software can predict the capacity of
each battery in the tested group.
d) The software shows the data in different formats, including bar charts, curve,
and form. You can magnify or minify any windows to read more details.
e) Automatically created EXCEL data reports make it convenient to send or
download data.
SBS-4815CT has diversified protective functions, which include the sounds alarm,
lights warning, and clear interface prompts.
SBS-4815CT is small in volume, light in weight, simple to operate, and a highly
accurate product. For different applications, SBS-4815CT works for discharging tests
of 24V, 48V battery strings.
1.2 System Component Unit
The SBS-4815CT battery capacity tester consists of main machine, wireless modules
for cells monitoring, wireless signal receiver and PC analysis software.
The main machine is organized by colorful LCD screen, data processing unit, data
monitoring unit, auxiliary power unit, power consuming unit and panel operation
unit.
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2. Main Technical Parameter
2.1 Environment & condition for use
2.1.1 Operating temperature
-5℃~ +50℃, full power, forced air cooling
2.1.2 Storage temperature
-40℃~ +70℃
2.1.3 Relative humidity
≤90% (40℃±2℃)
2.1.4 Altitude limit
0~2000m, -5℃~+50℃, full power
2000m～4000m, -5℃~+30℃, full power;
30℃~+50℃, decrease power for use.
2.2 Structure & Weight
With it’s stainless steel shell, SBS-4815CT has a sturdy and stable structure.
Meanwhile, the unique material of power consumption makes the SBS-4815CT main
machine portable.
The dimension (length*breadth*height):
SBS-4815CT: 400mm×220mm×200mm
SBS-4815CT Battery
discharge &
capacity tester
main machine
colorful LCD screen
data processing unit
data monitoring unit
auxiliary power unit
power consuming
unit
panel operation unit
wireless modules for
cells monitoring
PC analysis software
wireless signal
receiver
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Weight:
SBS-4815CT: 9.5 kg (main tester only)
2.3 Working Power Supply
SBS-4815CT: AC 220V/110V single phase 45Hz~65Hz
2.4 Input Voltage from Battery strings
SBS-4815CT: 20~60V
2.5 Discharge Current Range
Voltage range
current range
20-40V
0-75 A
40-60V
0-150 A
2.6 Parameter Display & Measure Accuracy
Parameter display: 5.7 inch LCD colorful 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
The protection design of SBS-4815CT:
2.7.1 the protections of DC input overvoltage, polarity reversal in battery connecting,
over current in discharging, and system overheat
2.7.2 when the discharging is abnormal, the warning light and buzzer would activate,
meanwhile the LCD screen shows a clear prompt.
2.8 Data Management & Communication
2.8.1 Discharge data management
a) The data can be saved continuously and automatically, so the test record will
not be lost even when the power is off.
b) support to manual inspection
c) support to read & download the data by communication port
d) display the residual space of internal memory
e) smart deleting selection: delete all or delete the selected record.
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2.8.2 Setting Work Parameters
With the “Preset” interface, you can set the discharge current, battery capacity, cells
number, the stop threshold value of battery string voltage and cell voltage, discharge
capacity, discharge time. The SBS-4815CT provides 8 locations to save the presetting
parameters for common usage.
2.8.3 Communication
a) Internal wireless signal receiver allows the SBS-4815CT to record the cell
monitoring & sampling data.
b) By RS232 port in the SBS-4815CT, your PC can connect with SBS-4815CT to
display real time discharge data.
c) By USB port in the SBS-4815CT, you can download the data to PC by USB-disk.
d) By parataxis control port, the SBS-4815CT can co-work with SBS-S series DC load
bank.
3. Basic Operational Principle
3.1 Battery Testing Principle
Because of the complexity of battery electric-chemical reaction and the diversity of
materials, structure, craftwork, and installation environments, battery strings from
different manufacturers can have many differences. Even the same type of batteries
from the same manufacturers cannot guarantee the same performance. Until now,
there is no a uniform method to check the quality of batteries easily and efficiently.
For lead-acid batteries—VRLA batteries, the common and effective test methods are
testing the cell voltage routinely and deep cycle discharging annually. We believe:
a) The battery voltage in floating charge status and the batteries capacities have no
correlation.
As we know, even the batteries which have a low capacity still can show a normal
voltage in floating charge status. So the person maintaining those batteries can’t
estimate the capacity based on the batteries voltage without discharging.
b) Deep cycle (full capacity) discharge is the most accurate method to test the
performance of batteries.
For the battery strings created by several cells in series, the actual capacity of
battery strings relies on the ability of the worst cell. So the goal of discharging your
battery string is to find the lag cells and replace the predict/know when to replace
the battery system.
Usually, battery discharge test needs to add constant current on the tested battery
strings, and monitor the voltage dropping status of each cell until it drops to the stop
threshold value. Based on the actual energy discharged, the discharge tester can
show the accurate capacity of the tested battery strings.
The voltage dropping curve in the discharging process:
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We know for different types, materials and craftwork, the voltage dropping data is
the most uniform and accurate evident for estimating the battery capacity. The
curve not only shows this information, but also shows that using different hour rates
to discharge the same batteries would yield different results. To avoid the harm of
discharging, your discharge has to apply the suitable hour rate.
3.2 Constant Current Principle
The internal circuit of the SBS-4815CT adopts PWM (pulse width modulation) control
technique. Under the control of central processing unit, the power circuit can
discharge the battery strings in the setting current accurately.
4. Operating Instructions
4.1 Environments Requirement
Please be certain there is NO CORROSIVE, NO EXPLOSIVE, NO ELECTRICAL
BREAKDOWN AIR OR CONDUCTIVE DUST.
4.2 Panel Description
Antenna
LCD screen
Air cooling fans
External current
measurement
Wired modules
input
USB port
RS232 port
Cable socket
AC input socket
Parallel input
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4.3 Main Machine Connection
Wireless module for 2V/6V/12V—SBS-2612
Power light (green)
Communicate light
(red)
Alligator clip
(4 yellow, 1 red, 1 black)
Wireless module for 1.2V/2V-SBS-12612
Power light (green)
Communicate light
(red)
Alligator clip
(4 red, 1 black)
Main machine
Voltage
measure socket
220VAC 50Hz or
110VAC 60Hz
Power Source
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4.3.1 Use the power cables (1 red, 1 black) to connect the main machine with the
battery string being tested.
4.3.2 Use the power supply cord to connect main machine with the AC power source
a) SBS-4815CT supports 110V AC 50Hz or 220V AC 60Hz external AC power source
4.4 Wireless Modules Connection
4.4.1 SBS-2/6/12 wireless modules (for 2V) connection
SBS-2612 Wireless module
Wireless module number and the battery to connect
For example: NO.1 module -- Connect the NO.1-NO.4 (from positive electrode)
NO.2 module -- Connect the NO.5-NO.8 (from positive electrode)
NO.3 module -- Connect the NO.9-NO.12 (from positive electrode)
………..
Red
Yellow 1
Black
Yellow 2
Yellow 3
Yellow 4
Power supply cord
Power Cable (red)
Power Cable (black)
Battery group
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176
TestEquipmentDepot.com
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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.
4.4.2 SBS-2/6/12 wireless modules (for 12V, 6V) connection
Cell
NO.1
Cell
NO.2
Cell
NO.3
Cell
NO.4
NO. 1 Wireless module
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
SBS-2612 Wireless module
Wireless module number and the battery to connect
For example: NO.1 module -- Connect the NO.1-NO.4 (from positive electrode)
NO.2 module -- Connect the NO.5-NO.8 (from positive electrode)
NO.3 module -- Connect the NO.9-NO.12 (from positive electrode)
………..
Cell
NO.1
Cell
NO.2
Cell
NO.3
Cell
NO.4
NO. 1 Wireless module
Yellow 1
Black
Yellow 2
Yellow 3
Yellow 4
Wiring Hint
Red
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4.4.2.1 Read the module number from the label in the modules, find the right
batteries to connect with. Do not connect the modules to 4 batteries no adjacent like
NO.1,3,8,9, it will probably damage the module immediately!
4.4.2.2 use the alligator clips (1 red, 1 black, 4 yellow) to connect modules with the
batteries, please follow the right wiring rule “Yellow 1 to Yellow 4, from long to
short”, and the wiring hint also print on the label of modules.
4.4.3 SBS-1.2/2 wireless modules (for 1.2V, 2V) connection
SBS-1.2/2 Wireless module
Wiring Hint
Wireless module number and the battery to connect
For example: NO.1 module -- Connect the NO.1-NO.4 (from positive)
NO.2 module -- Connect the NO.5-NO.8 (from positive)
NO.3 module -- Connect the 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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4.4.3.1 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
4 yellow 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 2V cell
Last four 6V/12V cell
Last three 2V cell
Last three 6V/12V cell
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
Module
Module
Module
Module
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Last two 2V cell
Last two 6V/12V cell
Last one 2V cell
Last one 6V/12V cell
4.4.4.2 SBS-1.2/2 wiring for last 4 to 1 cells
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module
Module
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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
No. 0 Spare module label
Module
Module
Module
Module
Module
Module
Module
Module
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Power switch
The welcome screen
The main menu
spare 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 module
If you run out of spare modules, and one of the assigned modules fails (for example,
No. 3 module fails) you can erase No.6 and reassign to No.3 for this urgent
requirement.
a) Open the No. 6 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 20-24
(normally on No. 6 module) have no data, it
means No. 6 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-4815CT 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.
4.5.3 SBS-4815CT input way: press on the screen directly
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Table
Chart
Preset
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.
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-4815CT supports manual setting in the discharge
interface without using the preset features.
Press “Preset”on the main menu to enter the preset interface
Back to the main menu
One screen can show 24 cells
If over 24 cells, press “Next”“Prev”
to see more
Preset parameter number
AhRate: The rated capacity of
the tested battery string
HourRate: The hour rate of
discharge
TestCurr: discharge current
BattSum: cell qty in battery
string
#Strings: string qty for single
discharge test
The highest & lowest voltage
cell in battery string
#BattLow: qty of cells which
voltages below “BattLowV”
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Parameter
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.
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”into the discharge interface
4.8.4 Press “Start” again to start discharge, the internal contactor will make a move.
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.
TimeSet: the discharge time
TestCapa: the capacity need
to be discharged
BattLowV: the lower limit
voltage of cells
GrpLowV: the lower limit
voltage of battery string
SaveTime: the time interval of
the data recording
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…..
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
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Discharge
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 The Data To PC
To load the preset you need
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 voltage,
“Table” & “Chart”screens
are similar with the one in
“BatteryView”
Change the parameters in the
process of discharging; all changes
can be activated immediately!
The used percentage of internal
memory, if this value is low please
delete some old data
The information of the data file
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Setup
4.10 System Setup
4.10.1 Press “Setup”in the main menu into setup interface
4.10.2 ‘BattLowAct’ give more options when you located some very bad cell in short
discharge but you want to remove them and proceed discharge more to know other
cells situation. Choose ‘Pause’, the discharge can be continued when you adjust
setting and ‘Start’ again, the whole process will be recorded in single data file.
Test time
& date
Delete the selected file
Delete all data file
If the data files are more than 1
page, use “Up” “Down” to browse
Plug USB disk into the USB port
Press “USB”to download the
selected file
Back to the main menu
Use PS232 wire to connect main
machine RS232 port with PC
Download the chosen file by
analysis software
Press “Modify”to locate the
parameters need to be changed, “+”,
“-”for change value
System date
& time
BattLowAct: the
operation when the
cells which voltage
reached the
“BattLowV” is over
‘#BattLow’: Stop or
Pause
BattOrder: wireless modules
connecting way, from the positive
or negative electrode to start
ConfigModuleAddr: assign spare
module to No. you need. Please follow
‘4.4.5.2 Activate No. 0 spare modules’
InputType: for
SBS-4815CT, this item
is locked at ‘Touch’
ModuleFreq: change frequency of
wireless receiver for working with
different Frequency wireless modules
Clamp range: change the external
current clamp range for different
clamp type(100A/200A/600A)
Cal: change Date to 2099-12-XX,
‘Cal’ button will be activated, for
going to ‘Calibration’ interface
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