SUNKKO 524D Battery Equalizer User Manual
- June 16, 2024
- SUNKKO
Table of Contents
SUNKKO 524D Battery Equalizer
Features and Advantages
- Nano amorphous isolated fully symmetrical transformer ensures the minimum voltage difference;
- American ultra-low internal resistance MOS devices constitute an ultra-low dynamic impedance inverter circuit. Achieve high power balance;
- The control and management of intelligent MCU chip realize automatic self-balancing;
- Automatically detect the minimum voltage of the battery, stop working when the battery energy is low, and protect the battery from power loss;
- Overcurrent fuse resistance at each series input end, to ensure safety;
- With active detection and voltage analysis function, the total voltage and average voltage cycle of the tested battery pack are displayed, and then the balancing effect is clear at a glance.
- Manual forced equalization timing off function, easy to use.
- Miniature circuit breaker device for over temperature and over-current protection, control the instantaneous abnormal excessive current, disconnect at over temperature, protect the normal and continuous balance of the battery pack.
Technical parameter
Product Name:| Lithium Battery Pack Transformer Inverter Active Equalization
Balancer
---|---
Product Model:| BAL-524D
Applicable battery type:| lithium ternary/lithium iron phosphate battery
Applicable number of battery strings:| 4 ~ 24 strings
Best balance effect:| 15mV
Recommended equalizing battery voltage:| above 3.2V
Equalizing current:| 0 ~ 5A
Power supply:| 1) Battery self-power (power supply of the fourth string) 2)
12V 2A adapter (power supply of the fourth string)
Interface:| 2.0/2.5/3.8/1 plug-in interface
Low voltage automatic shutdown:| 3V / string
Equalization mode:| Partial energy transfer mode
Power consumption in battery balance state after startup:| 80mA (voltage
difference = 10mV)
Working Principle
Equalization principle: high voltage energy is transferred to low voltage parallel transmission at the same time to realize battery voltage balance.
Schematic Diagram
Description of the Schematic Diagram: The diagram illustrates the connection of multiple inverters to a series of battery cells, indicating the flow of energy through the equalization process to balance the voltage across the cells.
Specifications
| Equalizing Current | 0-1-5A |
|---|---|
| Dimensions | Not specified in the images |
| Color | Blue and White with red LED indicators |
| Input Voltage | Not specified in the images |
FAQ
- What types of batteries is the BAL-524D compatible with?
- The BAL-524D is compatible with lithium ternary and lithium iron phosphate batteries.
- What is the maximum number of battery strings that can be connected?
- The device can handle 4 to 24 strings of batteries.
- What is the recommended equalizing current?
- It is recommended to use 0 to 5A for equalizing current.
- What should be done if the voltage of a ternary lithium battery is below 2.7V?
- If the ternary lithium battery voltage is lower than 2.7V or lithium iron phosphate battery is lower than 2.5V, the active equalization board does not start the equalization work.
- Can the BAL-524D be used with a protection board?
- Do not use the protection board line directly; the equalizer is not part of the protection board.
- What is the importance of the wiring sequence?
- Ensuring the correct wiring sequence is crucial. Misconnection can damage the active equalizer, and a poor contact or high resistance (over 50mΩ) will affect the balanced effect.
BAL-524D equalizer adopts the high-frequency transformer inversion and equipotential isolation coupling energy mode to realize the parallel connection of each series of batteries through the equipotential isolation coupling mode. Based on the parallel connection state, each series of batteries with different voltages can realize energy transmission and distribution and finally realize the high-power precision balance of the battery pack. The actual equalization work is carried out by the main control chip MCU, and the inverter with ultra-low dynamic impedance obtains more than 5A equalization current. Precise transformer technology and fully symmetrical circuit design can achieve the equalization effect of s 30mV. It is suitable for high-capacity ternary lithium battery pack and lithium iron phosphate battery pack, etc. The maximum equalizing current can reach SA, and the equalizing voltage difference can reach 30mV; Forced start switch is added to better solve the problem of poor equalization effect. (Equalizing Current 0.1-5A)
Features and Advantages
- Nano amorphous isolated fully symmetrical transformer ensures the minimum voltage difference;
- American ultra-low internal resistance MOS devices constitute an ultra-low dynamic impedance inverter circuit. Achieve high power balance;
- The control and management of intelligent MCU chip realize automatic self balancing;
- Automatically detect the minimum voltage of the battery, stop working when the battery energy is low, and protect the battery from power loss;
- Overcurrent fuse resistance at each series input end to ensure safety;
- With active detection and voltage analysis function, the total voltage and average voltage cycle of the tested battery pack are displayed, and the balancing effect is clear at a glance.
- Manual forced equalization timing off function, easy to use.
- Miniature circuit breaker device for over temperature and over-current protection, control the instantaneous abnormal excessive current, disconnect at over temperature, protect the normal and continuous balance of the battery pack.
Technical parameter
- Product Name: Lithium Battery Pack Transformer Inverter Active Equalization Balancer
- Product Model: BAL-524D
- Applicable battery type: lithium ternary/ lithium iron phosphate battery
- Applicable number of battery strings: 4 – 24 strings
- Best balance effect: 15mv
- Recommended equalizing battery voltage: above 3.2V
- Equalizing current: 0 – 5A
- Power supply: 1 )Battery self-power(power supply of the fourth string) 2) 12V 2A adapter(power supply of the fourth string)
- lnterface: 2.0/2.51/3.81 plug-in interface
- Low voltage automatic shutdown: 3V / string
- Equalization mode: Parallel energy transfer mode
- Power consumption in battery balance state after startup: B0mA (voltage difference = 1 0mV)
Working Principle
Equalization principle: high voltage energy is transferred to low voltage parallel transmission at the same time to realize battery voltage balance.
Schematic Diagram:
Display MODE
- Standby mode:
Correct connect the battery pack, the machine is in standby mode, display the total voltage of the battery pack. (The display can show up to 90V voltage, the total voltage is greater than 90V show-E, is a normal phenomenon) The blue LED always on,display the total voltage of battery pack.
2 Continuous equilibrium state:
Press the ” START * key,the machine is in a continuous equilibrium state,the screen cycles to display the total voltage of the battery pack and average voltage. Press the “START” key,stop equalising. The green LED always on,the red LED flashes, display the average voltage.
Test line sequence
Line sequence detection board
Before connecting the equalizing board, be sure to use the distributed line sequence test board to test whether the wiring sequence is wrong. The wrong line sequence will lead to the damage of the equalizing board. In that case, the board cannot be returned and replaced. Please pay attention.
Line sequence correct connection display
When the positive and negative wire sequence of the battery pack is correctly connected, the corresponding LED light is red
- Reverse polarity display
- When the sequence connection of two strings of wires is reversed, it shows the balanced arrangement of wires.
Operation Introduction
- Connect the positive pole of the battery pack in line sequence
- Connect the wire to the socket of 3.81 and pay attention to the locking screw
- Test line sequence with the detection board
- Pay attention the interface BO connect the negative pole(black) The total negative terminal (black wire) must be connected to the active equalizer socket “BO” (connect the total negative terminal first and then the positive plug at the back).
- Monitor the equalizing current real time with a digital clamp meter
Because the battery pack BMS protection cable is signal line for monitoring voltage.Overcurrent < 2A,affect the balanced effect.Therefore, suggest re-weld the cable ≥ 0.5mm?.
Battery pack descending series wiring diagram
With 2.0 and 2.54 pins(24S),use for protection board wiring.
Adapter power supply
- Equalizer supports external 12V/2A adapter power supply (This packing list of the equalizer not include adapter, you need to prepare your own fast-charging cell phone charger.)
- Wiring diagram
Packing list
- Active equalizer x1
- Line sequence detection board x1
- 3.81 cable interface x1
- Slotted screwdriver x1
- 0.5mm electronic wire x1
- DC line
Expand function-cascade connection
More than 24 strings of battery packs can be cascaded with 2 or more active equalizers. The following is the wiring schematic diagram of the cascade connection of the 32-string and 46-string battery packs. There must be multiple strings of repeated connections, and the more repeated strings, the better the effect.
- Two active balancers —The max number of strings of a battery pack is 25S~44S,
- Three active balancers -The max number of strings of the battery pack is 45S~64S,
- Four active balancers -The max number of strings of a battery pack is 65S~84S,
- Five active balancers —The max number of strings of a battery pack is 85S~ 104S,
- Six active balancers -The max number of strings of a battery pack is 105S~124S,
- Seven active balancers —The max number of strings of a battery pack is 105S~ 124S, And so on, which can “cascade” infinitely.
Wiring diagram
524D Battery Active equalizer
3.81 Connecting Interfaces wiring diagram
Note: If the ternary lithium battery is lower than 2.7V / lithium iron phosphate battery is lower than 2.5V, the active equalization board does not start the equalization work.
2.0/2.54 connecting interfaces wiring diagram
Equalizing current measure.
Do not use the protection board line directly!
Because the line of part of the protection board is only 0.1 square and is a signal line, the current can not exceed 2A. If it’s directly connected to the equalization board, it will be easy to overheat because of the large current, which has potential safety hazards. Equalizer boards using 5A and 8A must be rewired and the wire must not be less than 0.5 square.
The best usage conditions of active equalizer
- Be sure the wiring sequence is right. The misconnection will damage the active equalizer.
- Connect the equalizer, make sure the socket well-connected. A poor contact or high resistance(> 50m) will affect the balanced effect.
- Please re-weld the cable before use the equalizer, require the cross-sectional area cable > 0.5mm?
- If the battery pack ageing or damage, that can’t balance,have no effect.
- The equalizing current and time are affected by the resistance, capacity and wire resistance of the battery.
Explanation of equalizing current, equalizing time, equalizing connection and equalizing minimum differential pressure
-
The equalization current marked on the equalization module and equalizer is the maximum current that can be output or absorbed by the product, and it is also the maximum current allowed to flow through the chip on the product.
-
When the equalizer is actually used to equalize the battery pack, the equalized
current is affected by the following factors: -
Internal resistance of battery pack;
-
Resistance of connecting cable;
-
Contact resistance of connector;
-
Voltage difference between battery cells (unbalanced condition)
A: The smaller the internal resistance of battery pack, the greater the equilibrium current
B: The smaller the resistance of connecting wires and connectors, the greater the equilibrium current
C: The greater the voltage difference of the battery, the greater the equilibrium current
5A current test conditions:
Voltage difference between batteries ≥ 0.5V, connecting line battery < 8m Q (single wire) Internal resistance of battery ≤ 15m 0, connector resistance < 4m O -
Measurement method of equalizing current:
Since the equalizing current is affected by the loop resistance, the loop resistance will be increased and the equalizing current will be reduced when the ammeter is connected, so the access ammeter is not recommended. In addition, disconnecting the equalizing line during normal equalizing operation will lead to the risk of battery short circuit and damage to the equalizer. Therefore, the test current can only be measured by DC Clamp ammeter. -
Equilibrium time correlation
A: Under the condition of the same internal resistance of battery, if it can work in equilibrium with the maximum current, the time will be shorter, and the smaller the resistance of connecting line and connector, the shorter the time will be.
B: The equalization time of high-capacity battery pack will be longer.
C: The smaller the equalizing voltage difference, the longer the time.
D:In the final stage of equalization, the voltage difference is very small, so the current is also very small, this period takes a long time.
E: When active continuous online equalization is adopted, the equalization state is ideal, and the battery voltage difference can also be controlled between 30mv-80mv. You don’t need to pay attention to time by this way.
About the connection of equalizer and battery pack:
- The connection mode of the connector on the equalizer product is based on the convenience of users’ installation and use. However, because the connector has a contact resistance of 3~10ml, each string of batteries will increase 2×3~10=6~20ml, which will greatly reduce the equalization current. Therefore, it is recommended to cancel the connector and connect it directly with wires;
- Larger cross-sectional area and shorter connection shall be adopted as far as possible for the connecting wire between the battery pack and the battery pack;
- When direct wire connection is adopted, one end of the equalizer must be welded first, and the battery pack end shall be connected (welded) when it is firmly welded. Pay attention to prevent short circuit between wires during operation!
- In order to obtain a larger balanced current value, it is recommended to use 0.5mm A when selecting the connecting wire. If the equalizer is far away from the battery pack and needs to be extended, the conductor section needs to be increased proportionally.
About the voltage difference between battery strings after equalization:
- The min voltage difference of 524D series design is ≤30mV (actually15~20mv);
- The min voltage difference after equalization is related to the equalization time. The longer the equalization time is, the smaller the pressure difference is;
- The minimum voltage difference after equalization is related to the battery internal resistance, connecting line resistance and connector resistance. The smaller the resistance is, the smaller the pressure difference is.
About the voltage difference between battery strings after equalization:
The 524D equalizer adopts the high-frequency transformer inversion and equipotential isolation coupling energy mode to realize the parallel connection of each series of batteries through the equipotential isolation coupling mode. Based on the parallel connection state, each series of batteries with different voltages can realize energy transmission and distribution, and finally realize the high-power precision balance of the battery pack. The actual equalization work is carried out by the main control chip MCU, and the inverter with ultra-low dynamic impedance obtains more than 5A equalization current. Precise transformer technology and fully symmetrical circuit design can achieve the equalization effect of ≤ 30mV.
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