SmartSafe iSmartEV ED500 User manual

iSmartEV ED500 User Manualwww.newsmartsafe.com
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Copyright Information
Copyright © 2021 by SHENZHEN SMARTSAFE TECH CO.,LTD. All rights reserved. No part of this
publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means,
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damages, losses, costs, or expenses incurred by purchaser or third parties as a result of: Accident,
misuse, or abuse of this unit, or unauthorized modifications, repairs, or alterations to this unit, or failure
to strictly comply with SMARTSAFE operating and maintenance instructions. SMARTSAFE shall not be
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is a registered trademark of SHENZHEN SMARTSAFE TECH CO.,LTD. in China and
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Contents
1. Product Overview .....................................................................................................................................1
1.1 Product Features ................................................................................................................................... 1
1.2 Main Function and Test Range ............................................................................................................. 1
1.3 System Components ............................................................................................................................. 1
1.4 Working Conditions ................................................................................................................................1
1.5 Environment & Energy Impact ...............................................................................................................1
1.6 Protection & Alarm .................................................................................................................................2
2. Precautions for Safe Use ........................................................................................................................ 2
2.1 Safe Working Period & Production Date ...............................................................................................2
2.2 General Rule ..........................................................................................................................................2
2.3 Common Incorrect Operation ................................................................................................................ 2
2.4 Damage Probably Caused By Incorrect Operation ...............................................................................2
2.5 Emergency Treatment In Exceptional Cases ........................................................................................2
2.6 Precautions In Exceptional Circumstances ...........................................................................................2
2.7 Other Safety Alerts ................................................................................................................................ 2
3. Technical Features ...................................................................................................................................3
4. Operating Instructions ............................................................................................................................ 4
4.1 Panel Description ...................................................................................................................................4
4.2 Interface Pin Definition ...........................................................................................................................4
4.3 Main Unit Connection ............................................................................................................................ 5
4.4 Main Unit Operation ...............................................................................................................................8
4.5 Discharge & Charge .............................................................................................................................. 8
4.6 Equalization ......................................................................................................................................... 13
4.7 System Settings ...................................................................................................................................20
5. Fault Analysis and Troubleshooting ................................................................................................... 24
6. Transport & Storage .............................................................................................................................. 24
7. Environmental Protection and Others .................................................................................................24
Warranty ...................................................................................................................................................... 25

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1. Product Overview
iSmartEV ED500 battery maintenance tester integrates battery string discharge-charge and cell
equalization functions into one unit. It is applicable in battery discharge-charge test and multi-channel
cell equalization test.
1.1 Product Features
•Adopt the latest equalizing maintenance technology and avoid the interference to BMS (Battery
Management System), iSmartEV ED500 is designed for lithium battery pack daily discharge, charge,
and equalizing maintenance.
•Based on wide voltage range design, iSmartEV ED500 can be applied to lithium battery packs testing
with various voltage levels.
•Equalizing maintenance test mode can activate the lithium battery performance completely.
•Voltage and temperature monitoring and protection during test can prevent over-charge and over-
discharge.
•Multiple discharge auto-stop conditions make testing mode more intelligent and flexible, and avoid
over-charge and over-discharge.
•Intelligent equalizing function based on each cell voltage monitoring and equalizing charge.
•Support equalizing maintenance parameter customization.
•Support multiple protection design and alarm settings of voltage, current, temperature abnormal to
protect the battery and the tester.
•Support functions such as overvoltage, undervoltage, overcurrent, output short circuit, anti-reverse
protection and overheating protection.
•Adopt wave width modulation technology, high efficiency, high power factor, low noise, low
electromagnetic interference.
•7-inch touch screen, easy to operate.
•Built in memory, supporting automatic storage of operation records.
•Portable design, easy to carry and transport.
1.2 Main Function and Test Range
Mainly used for lithium battery pack charge & discharge test and equalizing maintenance, suitable
for various voltage levels.
1.3 System Components
The device consists of main unit, test cables, cell voltage acquisition kit (CAN communication
kit/physical sampling kit), AC power cord. Please check the actual configuration subject to the packing
list.
The main unit is organized by LCD touch screen, data processing unit, data acquisition unit,
auxiliary power unit, discharge unit, charge unit, equalization unit, and panel operating unit.
1.4 Working Conditions
NO CORROSIVE, NO EXPLOSIVE, NO ELECTRICAL BREAKDOWN AIR OR CONDUCTIVE
DUST.
1.5 Environment & Energy Impact
The tester can convert the tested battery energy into heat and use cooling system to blow the heat

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out of the unit, so during the discharge test, please pay more attention to heat dissipation and ventilation.
1.6 Protection & Alarm
This tester has hardware and software protection functions such as reverse connection, overvoltage,
overcurrent, overtemperature, communication error, etc.
2. Precautions for Safe Use
2.1 Safe Working Period & Production Date
The designed safe working period for this tester is 5 years, please refer to the factory inspection list for
the production date.
2.2 General Rule
Please follow the user manual to use this tester.
2.3 Common Incorrect Operation
1）Tools for connecting is not well insulated.
2）Operating without following the user manual.
2.4 Damage Probably Caused By Incorrect Operation
1）Short circuit accident: Tools is not well insulated, or battery pack positive and negative electrodes
are too close.
2）Failure to follow the correct operation method will cause the device not working properly.
2.5 Emergency Treatment In Exceptional Cases
Disconnect the device power supply and test cables.
2.6 Precautions In Exceptional Circumstances
If the operator uses tools without well insulation or improper operate to cause short circuit, please
separate the cables immediately.
2.7 Other Safety Alerts
Strict compliance with safety operating norms and correct operating procedure.

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3. Technical Features
Function Parameter
Model iSmartEV ED500
Power input AC 90~265V
Charging & discharging
voltage range 2~260V
Voltage measurement
accuracy ±0.2%FS+0.1V
Charging & discharging
current range 0~ 100A
Current measurement
accuracy ±0.5%FS + 0.1A
Test Power Charge: 4.4kW max
Discharge: 7.2kW max
Equalization Voltage 1.8~4.5V
Equalization Current 0~5A
Test Cell Qty 24
Temp Accuracy ±2°C (-25°C~85°C)
Charge Mode constant current + constant voltage
Discharge Mode Constant current + constant voltage
Protections Overcurrent and overvoltage protection for input and output
Communication CAN/RS485: cell data acquisition
USB: data export & system upgrade
Safety Testing
Breaking down test AC input-metal shell: 2200Vdc 1min
DC input-metal shell: 2200Vdc 1min
Working Environment
Cooling Forced air cooling
Temperature Operating temperature: -5~40℃; Storage temperature: -20~70℃
Humidity Relative humidity 0-90% (40±2℃)
Elevation Rated altitude of 2000 meters
Size and Weight
Dimension 643*404*540mm
Weight 42kg

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4. Operating Instructions
4.1 Panel Description
NO. Part Name
1 Handle
2 USB Port
3 Display
4 Expansion Port
5 Temp Acquisition Port
6 Equalization Unit Port #2
7 Equalization Unit Port #1
NO. Part Name
8DC Test Cable Positive &
Negative Interface
9 Voltage Sense Port
10 AC Input Socket
11 AC Breaker
12 DC Breaker
13 Emergency Stop Button
4.2 Interface Pin Definition
1) 16 Pin Equalization port
Pin_SN Description Line Marker Pin_SN Definition Line Marker
1 Cell #1 - B1- 9 Cell #8 + B8+
2 Cell #1 + B1+ 10 Cell #9 + B9+
3 Cell #2 + B2+ 11 Cell #10 + B10+
4 Cell #3 + B3+ 12 Cell #11 + B11+

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5 Cell #4 + B4+ 13 Cell #12 + B12+
6 Cell #5# + B5+ 14 Null Null
7 Cell #6 + B6+ 15 Null Null
8 Cell #7 + B7+ 16 Null Null
2) 24 Pin Temp port #2
Pin_SN Description Line Marker Pin_SN Definition Line Marker
24 Temperature
Acquisition T4 T4 12 Null Null
23 11 Null Null
22 Temperature
Acquisition T3 T3 10 Null Null
21 9 Null Null
20 Temperature
Acquisition T2 T2 8 Null Null
19 7 Null Null
18 Temperature
Acquisition T1 T1 6 Null Null
17 5 Null Null
16 Null Null 4 Null Null
15 Null Null 3 Null Null
14 Null Null 2 Null Null
13 Null Null 1 Null Null
3) Expansion Port
Pin_SN Description
1 RS485 A
2 RS485 B
3 Micro_USB-VCC
4 Null
5 Micro_USB-GND
6 Micro_USB-D+
7 Micro_USB-D-
4.3 Main Unit Connection
4.3.1 Working Power Supply Connecting
Connect the power supply cord with the main unit AC socket, and select the corresponding power cord
according to the load output connected to the power socket.

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4.3.2 Discharge-Charge Test Scenarios
First, insert the DC test cable into the positive and negative interface of the equipment (red for positive
and black for negative), and connect the other end of the DC test cable to both ends of the battery pack
(red for positive and black for negative).
Then connect the equalization bus-harness to any equalizing test socket of the tester, and plug the
equalization bus-harness and the equalization subharness,
Finally clamp the clamps of the equalization subharness on the battery module under test in turn.

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According to the wire label on the equalization subharness, B1 - is connected to the negative electrode
of No. 1 single cell (B1), B1 + is connected to the positive electrode of No. 1 single cell (B1), B2 + is
connected to the positive electrode of No. 2 single cell (B2), and connected in sequence.
Note: the nearest to the negative terminal of the battery module is the No. 1 single cell.
4.3.3 Equalization Test Scenarios
Firstly connect the equalization bus-harness to the equalizing test socket of the tester, then plug the
equalization bus-harness and the equalization subharness, and finally clamp the clamps of the
equalization subharness on the battery module under test in turn.
Please connect the cables strictly according to the instruction. For connecting with all plugs and sockets,
please observe the positioning grooves and holes, confirm the plug's correct direction and check the
connecting is fastened after joining.

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4.4 Main Unit Operation
4.4.1 Welcome Screen
4.4.2 Main Menu
Click the function module on the main menu to enter the corresponding function operation interface.
4.5 Discharge & Charge
Click “Discharge-Charge” on the main menu to enter the corresponding function operation interface.

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4.5.1 Discharge Test
1）The function “Discharge” is a single discharge test mode.

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Parameter Description：
Battery Information
Battery Name
The naming of the battery pack or module.
Rated Capacity
The rated capacity of the battery pack, according to the
actual input, can be identified from the rating plate.
Battery Type
Select battery type.
Cell Quantity
Fill in according to the actual number of strings.
Cell Voltage Difference
Differential voltage protection value, one of the shutdown
conditions.
Discharge Parameters
Discharge Current
Discharge test current value.
Discharge Time
Discharge test time setting, one of the shutdown
conditions.
String Low Limit
Group end voltage lower limit protection, one of the
shutdown conditions.
Discharge Capacity
Discharge capacity ah, one of the shutdown conditions.
Cell Low Limit
Single string lower limit voltage protection value, one of
the shutdown conditions.
2）Click to save configuration and enter the test interface. Close the DC switch, tap Start to start the
test.
The current battery status, the test current, the test duration, the current voltage of the battery pack and
the cell information can be viewed on the test interface. The configuration can be modified during the test.
3）In the process of threshold protection test, if any shutdown threshold is reached, it will stop
automatically. Type of shutdown conditions: discharge time, lower limit of group end, pre-discharge
capacity (in case of opening discharge capacity limitation) and cell lower limit (in case of opening
discharge capacity limitation).
4）In addition to the above shutdown threshold protection, there are also multiple hardware protections:
abnormal voltage of discharge module, abnormal current of discharge module, abnormal temperature of
discharge module, short circuit protection and fan failure.
4.5.2 Charge Test
1）The function “Charge” is a single charge test mode.

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Parameter Description：
Battery Information
Battery Name
The naming of the battery pack or module.
Rated Capacity
The rated capacity of the battery pack, according to the
actual input, can be identified from the rating plate.
Battery Type
Select battery type.
Cell Quantity
Fill in according to the actual number of strings.
Cell Voltage Difference
Differential voltage protection value, one of the shutdown
conditions.
Charge Parameters
Charge Voltage
The target value of the charging voltage.
Charge Threshold
The upper limit voltage protection value of the group
end, one of the shutdown conditions.
Charge Current
Charging test current value.
End Current
When the voltage reaches, the current is less than the
value, then it stops, and one of the shutdown conditions.
Charge time
Charging test time, one of the shutdown conditions.
Cell Up Limit
Single core voltage upper limit protection value, one of
the shutdown conditions.
2）Click to save configuration and enter the test interface. Close the DC switch, tap Start to start the
test.

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The current battery status, the test current, the test duration, the current voltage of the battery pack and
the cell information can be viewed on the test interface. The configuration can be modified during the test.
3）In the process of threshold protection test, if any shutdown threshold is reached, it will stop
automatically. Type of shutdown conditions: charge time, current threshold, upper limit of cell voltage
and group voltage.
4）In addition to the above shutdown threshold protection, there are also multiple hardware protections:
charging module undervoltage protection, charging module overvoltage protection, charging module
overtemperature protection, charging module overcurrent protection, short circuit protection and fan
failure, etc.
4.5.3 Data Management

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Insert a U-disk into the USB port on the panel, select the data to be saved, and tap USB button to
transfer the corresponding discharge data and charge data to the U-disk.
4.6 Equalization
Tap Eualization in the main interface to enter the following interface.
4.6.1 Parameters
The tester can maintain at most 2 groups of batteries, each with 12 batteries (subject to the number of
connected batteries).
When power on, if the battery pack is connected correctly, the current status of the battery pack will be
displayed after the battery pack number. If the battery pack is not connected or there is a connection
failure, the display status is: unconnected.

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Parameters Parameter Description Parameters Parameter Description
Item
Display the battery pack
number and the status of the
battery pack.
Test Mode Charge, discharge or equalizing
Test Time Work time since test started. Battery Type The type of lithium battery pack.
Cell Qty Cell quantity in a battery
pack.
Target
Voltage
The end voltage to terminate the
testing.
Max Voltage The max voltage in all cells. Min Voltage The min voltage in all cells.
Temperature Max temperature measured in
battery pack. Operation Start/stop discharge, charge or equalizing.
4.6.2 Battery Pack Settings
On the "Equalization" interface, tap Settings button below the battery pack to enter the corresponding
setting interface for the battery pack.
1）String Name: Enter the battery pack number or the corresponding information for testing to name it.
2）Test Mode: Click the drop-down menu to select the corresponding work mode (charge, discharge or
equalizing).
3）Battery Type: Click the drop-down menu to select the appropriate lithium battery pack.

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4）Cell Qty: Click the drop-down menu to select the corresponding cell number of the test battery pack.
5）Test Object: Click Select All to select all batteries; deselect all, then click the battery that requiring to
be tested.

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6）Voltage Threshold: Input the end voltage to terminate the testing.
7）Current: Input the max discharge or charge current.

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8）click to save the adjustment, and click back to the testing interface.
4.6.3 Start the Test
1）On the "Equalization" interface, tap Start button to start the test.

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2）Tap Details to view parameters such as cell voltage, working current, working status, test duration,
and capacity of the corresponding test battery pack.
3）Equalization Finished Conditions：
•When the cell voltage reach the voltage threshold, and current is less than 0.2A over 3 mins, the unit
will display Finished on this cell channel.
•All working cell channels display ‘Finished’, the whole equalization is complete.
4.6.4 Data Analysis
After the test is completed, the test data is displayed in column chart or curve mode.
Tap Bar Chart, the test data voltage is displayed as a bar graph.