AUTEL CDT100 Battery Discharge Charge Unit User Manual

CDT100 Battery Discharge Charge
Unit User Manual AC MaxiEV CDT100
USER MANUAL
BATTERY DISCHARGE-CHARGE UNIT

OVERVIEW

MaxiEV CDT100 Battery Discharge-Charge Unit is an all-in-one instrument for charging and discharging lithium batteries with a voltage range of 2-285V. It incorporates various testing and maintenance modes tailored to lithium batteries’ charging and discharging characteristics. This unit enables discharge and charge tests for lithium batteries.
The large screen interface, user-friendly operation, and intuitive UI design make it easy for users to maintain and manage battery packs scientifically, thereby extending their service life.
It can be widely used in storage maintenance, aftermarket lithium battery modules/packs maintenance, and other scenarios.
1.1 Features

• Multi-function into one unit: collecting discharge, charging, and charge discharge cycle (activation) function into one, just one device can complete all test and maintenance works of the battery maintenance technician
• Built-in various maintenance modes for lithium battery: the optimal charge and discharge mode can be selected according to the type of battery to achieve the best test maintenance effect.
• Wide voltage design: it is suitable for testing all kinds of lithium battery modules/packs with voltage levels of 2-285V.
• Multiple discharge modes: supports constant current, constant power discharge mode, can simulate a variety of actual battery packs with load working conditions scenarios, and comprehensive test battery pack performance.
• High-efficiency charging: complete three-stage charging mode (constant current-constant voltage-floating charge) to improve charging efficiency;
• Battery activation (optional): supports adding the cycle function to set charge and discharge rules and cycle times freely, effectively agitating the battery activity and improving the battery pack capacity.
• Cell voltage acquisition: the device collects cell voltage in real-time by CAN communication or physical sampling mode, which can quickly and accurately measure capacity during the charging and discharging test and protect the battery from damage due to over-discharge and overcharging.
• Multiple protections: It supports adequate protection for various abnormal conditions during the test process. The system triggers the automatic termination of the test; the LCD prompts and beep warning to assist users in proper processing.
• Highly intellectualization: using an intelligent operating system, large screen interaction, straightforward operation, and humanized UI design makes maintenance work more intelligent, efficient, and accurate
• Calibration correction: The device’s voltage and current values can be calibrated and corrected at any time to ensure measurement accuracy.

1.2 System Component Unit
MaxiEV CDT100 Battery Discharge-Charge Unit configured with a main unit, test cables, data acquisition cables, AC power cord, USB disk, user manual, and carrying case. 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, and charging unit.

1.3 Impact on the Environment and Energy
The built-in load of the device discharges the battery. The discharge test will convert the battery’s chemical energy into heat energy. Please notice heat dissipation and ventilation of the test area.
1.4 Device Safety
The device is equipped with multi-protection of reverse connection, overvoltage, over-current, over-temperature, communication, etc.

Safety Precautions

2.1 Operator Requirements

Alarm

1. Operators are required to receive training related to the use of the equipment before operating.
2. Before operating, operators should read the user manual and the related regulations.
   2.2 Operating Environment
   Alarm
3. Operating temperature: -5~50°C
4. Relative humidity: 0~90% (40±2°C); rainy-day outdoor use is prohibited.
5. Non-corrosive, explosive, and destructive insulation gases and conductive dust of the test environment are required.
6. Ensure ventilation of the operating environment.
   2.3 Connection Precaution
   Alarm
7. Ensure the unit’s AC input breaker and DC breaker stay off before connecting the cables.
8. Please strictly follow the instructions to connect the cables properly.
   Danger
9. Warning signs need to be placed in the test work area to avoid the risk of tripping over the cable.
10. Place the equipment properly to avoid danger caused by equipment movement during the test.
    Danger
    When the equipment is running, it is necessary to ensure that the air inlet and outlet are free of obstructions.
    2.4 Operating Precautions
    The operation of the device is by touching the screen input. Please follow the screen prompts. Close the DC breaker before executing the charge/discharge test.
    Danger
11. The maximum output voltage of this device is 285Vdc. Please pay attention to personal safety.
12. The working power of this device is AC input. Please make sure the operating power is reliably grounded.
    Danger
    The device in the discharge test process will emit a lot of heat. The temperature of the air outlet is high. Please do not approach or touch to avoid high temperature burns.
    Danger
    When the discharge test is finished, please do not shut down the device immediately if you do not continue with the charging test. Run continuously and wait for the built-in fan to dissipate the heat for at least 3 minutes before shutting
    down. Avoid scald caused by the operator accidentally touching the hot air outlet when transferring the device.
    2.5 Common Misoperation
13. Operating tools are not insulated.
14. Operating the device without following the user manual.
    2.6 Possible Damage Caused by Misoperation
15. The operating tool is not insulated. The positive and negative poles of the battery pack are too close to cause a short circuit accident.
16. If you are not operating correctly, it will fail to start the test.
    2.7 Emergency Treatments on Abnormal Conditions
    Disconnect the unit’s operating power and test cables.
    2.8 Precaution of Special Conditions
    Disconnect the cable in time if the operator does not make insulation measures or causes a short circuit due to improper operation.
    2.9 Other Safety Warnings
    Strictly observe safe operating practices and correct operation methods.

Main Technical Parameter

Charge/Discharge Technical Index
Voltage Range| 2~285V (working voltage range: 2~250V; max range: 285V)
Discharge Current| 0~150A
Charging Current| 0~100A
Discharge Power| 7.2kW max
Charging Power| 4.4kW max (220Vac supply);
2.2kW max (110Vac supply)
Discharge Mode| constant current, constant power
Charge Control| constant current + constant voltage
Protection| • input overvoltage, LCD promote+beep warning
• battery polarity reverse connection, LCD promote+beep warning
• overcurrent, LCD promote+beep warning
• overheat, LCD promote+beep warning
• communication alarm, LCD promote+beep warning
Accuracy| test current ≤±1%FS+0.2A;  module voltage≤±0.5%FS+0.3V; cell voltage: ≤±0.1%FS+5mV
Communication| RS485, USB
Internal Memory| 8G
Working Condition
Cooling Mode| forced-air cooling
Temperature| working: -5~50°C; storage: -20~70°C
Humidity| RH: 0~90%(40±2°C)
Rated Altitude| 4000m
Noise| ﹤60dB
Working Power
Voltage| single-phase three-wire 100-264Vac, frequency: 45~65Hz
Withstand Voltage| input-shell: 2200Vdc 1min / input-output: 2200Vdc 1min / output-shell: 700Vdc 1min
Mechanical Character
Dimension| 530x300x350mm
Weight| 23.4kg

Installation

This device is mobile portable equipment and does not involve installation.

Device Description

5.1 Panel Description

(black)
7| Test Cable Socket (+)| connect with the charge-discharge cable (red)
8| Antenna| to enhance the received signal
9| Emergency Stop Button| for emergency stop the test
10| DC Breaker| DC side closing switch
11| AC Input Power Switch| device’s power switch
12| AC Input Socket| 100-264Vac single-phase three-wire input socket

5.2 Cables Description
There are 3 types of cables for MaxiEV CDT100 tester : DC Test Cables, Data Acquisition Cables, and AC Power Supply Cables.
A. DC Test Cables
Discharge-Charge cables for the test; connect with the device end and battery module/pack poles.
Note: Must follow the red-positive/black-negative principle. B. Data Acquisition Cables
24CH Sampling Box

1. 24CH Box Comm Wire
   For 24CH sampling box communication; connect with the 24CH sampling box and the extend (comm) port of the tester.

2. Cell Acquisition Harness – Clips Type
   For cell voltage collecting; connect with cell ends follow clip marks and clip in order from B1-, B1+, B2+…B12+ with the cell poles. 3) Temp Acquisition Wire
   For temperature data collecting; connect with the T1~T4 terminals of the 24CH sampling box and the battery.

C. AC Power Cord

1. 10A (max) Power Cord
   Supports a maximum of 2.2kW for discharging power, and connects to the power socket.
   There are two power cords with different plugs for meeting: European Standard: 220Vac single phase three-wire, 2.2kW max.
   American Standard: 110Vac single phase three-wire and the power will be halved.
   Note: Please see the real product for detailed information.
2. 20A (max) Power Cord
   Supports a maximum of 4.4kW for charging power when connected to a 220Vac distribution box.
   When connected with the 110Vac power input, the power will be halved.

Note:

• Please refer to the provided image for reference. Actual product details may vary slightly.
• The average service life of the harness connector is about 200-300 times. Please check and replace it regularly.
• Please refer to the packing list with the shipment for the actual configuration.

5.3 24CH Terminal Definition

**1 13 Pin + 12 Pin Terminal Block**

No.| Definition| Note| No.| Definition| Note
00| cell 1# – negative| B1-| 13| cell 13# – positive| B13+
01| cell 1# – positive| B1+| 14| cell 14# – positive| B14+
02| cell 2# – positive| B2+| 15| cell 15# – positive| B15+
03| cell 3# – positive| B3+| 16| cell 16# – positive| B16+
04| cell 4# – positive| B4+| 17| cell 17# – positive| B17+
05| cell 5# – positive| B5+| 18| cell 18# – positive| B18+
06| cell 6# – positive| B6+| 19| cell 19# – positive| B19+
07| cell 7# – positive| B7+| 20| cell 20# – positive| B20+
08| cell 8# – positive| B8+| 21| cell 21# – positive| B21+
09| cell 9# – positive| B9+| 22| cell 22# – positive| B22+
10| cell 10# – positive| B10+| 23| cell 23# – positive| B23+
11| cell 11# – positive| B11+| 24| cell 24# – positive| B24+
12| cell 12# – positive| B12+| | |
Note:
1)  A total of 24 cells’ data can be collected. Users can cascade additional sampling boxes for single string cells over 24.
2)  Most manufacturers’ cell numbers start with the negative end.
3) A total of 25 positions and the 00# pin is the first cell position, which is connected to the negative of the starting cell (1# cell).

2 8 Pin Terminal Block
No.| Definition| Note| No.| Definition| Note
T1| temp point 1| 1-, 1+| T3| temp point 3| 3-, 3+
T2| temp point 2| 2-, 2+| T4| temp point 4| 4-, 4+
Note:
1) It is an optional function. Please check the configuration with the manufacturer before ordering.
2) To access the temperature monitoring or NTC analysis, you must set the thermal coefficient value.

Connecting Diagram

Please do not switch on the device before connecting!
6.1 DC Test Cable Connection
Following the red-positive and black-negative principle, connect the test cables to the device’s test cable sockets and the battery’s positive and negative terminals.

1. Connect test cable camlock connectors with the test cable sockets on the panel following the corresponding colors.
2. Connect the other ends of test cables with two poles of the battery pack, the screws for connecting must be securely fastened.

6.2 Cell Voltage Acquisition Connection
The tester will equip a 24CH Sampling Box to monitor the cell data. One box can monitor 24 cells, and users can cascade additional sampling boxes for single string cells over 24.
Additionally, we offer various cell sampling harnesses to suit different battery structures and support customized tooling options to meet specific requirements. The following explains a common type of connection: Clips-type harness.
The clips-type sampling harness is suitable for the unpacked battery test. Users can directly connect the cell poles with clips or other customized fixtures. The following will take clips connection of a 1P12S battery module with opened cover as an example.

Connection Cables Required:
A. DC Test Cables ( )
B. Data Acquisition Cables

1. 24CH Box Comm Wire ( )
2. Cell Acquisition Harness – Clips Type
   Connecting Order:

1. Connect the 24CH Box Comm Wire with the device’s communication port and input (IN) port of the 24CH Sampling Box.
2. Follow clip markers, and join in order from B1- (black), B1+, B2+…B12+ with the cell poles of the battery. (Note: please confirm the cell sequence first, then clip cells in sequence accordingly.)
3. Connect the cell acquisition harness with the 24CH Sampling Box.

6.3 Temp Acquisition Wire Connection
The 24CH Sampling Box is equipped with a temperature monitoring function.
Connect one end to the T1~T4 terminal, and contact the four temperature sensors to different positions of the battery to obtain the temperature value.
6.4 AC Power Cord Connection
MaxiEV CDT100 configured different power cords for realizing charging with different power.
a) Connect one end of the 10A power cord to the AC Power Input of the tester, and connect the other end to the 110Vac/220Vac power socket, the max power can reach 2.2kW. (Please note that the power will be halved when connecting to 110Vac power input.)
b) Connect one end of the 20A power cord to the AC Power Input of the tester, and connect the other end to the 110Vac/220Vac distribution box, the max power can reach 4.4kW. (Please note that the power will be halved when connecting to 110Vac power input.)
Please ensure the max charging current is set appropriately based on the AC input load to prevent overcurrent.
Note: Please connect the cables strictly according to the instructions. For connecting with all plugs and sockets, please observe the positioning grooves and holes, confirm the plug’s correct direction, and check that the connecting is fastened after joining.

Operating Instruction

After the device connection, turn on the AC Power Switch to start up. The device will show the Welcome Page and the operating system is automatically loaded to enter the Main Menu Page, including Discharge, Charge, Data, and Settings.

7.1 Settings
Press the Settings on the Main Menu Page to set system parameters.
7.1.1 General Setting

1. Date & Time
   Press Date & Time to modify the system’s date and time by scrolling numbers or pressing the item to input values directly. Press OK to save.

2. Wi-Fi Connection
   It is mainly used to upgrade the device OS and firmware module program online. Press Wi-Fi Connection, choose the wireless network and input the password to connect. Press to back to the Settings Page.

3. Language
   The system supports three language switching, including English, Simplified Chinese, and Traditional Chinese. After confirming the language switch, the device will restart.

4. Enable Screenshots
   The system supports the screenshots function. Press and hold the page title or the Note title for 5 seconds to capture the screen. The screenshots can be exported via the USB disk.
   Enable the function by checking the “” symbol.

7.1.2 24CH Sampling Box Data Acquisition
The device supports collecting data by a 24-channel sampling box.

1. Data Acquisition Mode
   Display the data collecting mode and no need to modify it.

2. K value and B value
   Set the KB Value and read/input according to the actual NTC KB value of the battery.

3. Module Add
   It is used to check and add a sampling box address. The device comes standard with one 24CH sampling box, which supports testing up to 24 cells. The box can cascade if the quantity of test cells exceeds 24.

4. Cell Sequence: Positive/Negative
   Choose the sequence of cell numbers that start from Positive or Negative by actual (default: Negative).

5. Acquisition Box: Enable/Disable
   Enable/Disable the module sampling kit (accessory) during the test. Please check by actual.

6. Sampling Interval
   To set the interval for saving data, input the value, and press OK to save (default: 10s).

7.1.3 Data Rentention
The system supports continuing to record data when completing the test. Users can set the continuous recording time. 7.1.4 Log Management

The options in this part are to provide the running logs to the manufacturer by local/online way for fault diagnosis. Please do not operate by yourself.
7.1.5 FMW & System Update

1. FMW Upgrade
   The two items are used for local or online software upgrades of the device firmware modules.
   • FMW Module Update : Insert a USB disk with the upgrade program into the USB Port of the tester. Name the program Unit. bin and put it in the root directory. Select the upgrade program to complete the upgrade.
   • FMW Online Update: Users need to confirm an available upgrade file with the manufacturer and send them the Device ID. Connect a network in the Wi-Fi Connection function, and the system will automatically receive the update package.

2. System Upgrade
   The two items are used for local or online software upgrades of the device operating system.
   • System Update: Insert a USB disk with the upgrade program into the USB Port of the tester. Name the program update. apk, put it in the root directory, and select the upgrade program to complete the upgrade.
   • Sys Online Update: Users need to confirm an available upgrade file with the manufacturer and send them the Device ID. Connect a network in the Wi-Fi Connection function, and the system will automatically check the current version and receive the upgrade package.

3. Device ID
   It’s for device identification management.

7.2 Discharge
The Discharge function is a single discharge test mode. Press the Discharge icon on the Main Menu Page, and the system will first enter the Parameters Setting Page.

7.2.1 Parameters
The Parameters Setting Page will display the parameters of the last test.
Users can create, read and save the test parameters on this page.

Battery Name:
Rated Capacity:| Name the battery   for the    tested   battery recognition.
The nominal capacity of the battery.| –
–
Battery Type:| The type of    tested battery,    LiFePO4, Li(NiCoMn)O2, LiTiO, and LiMnO2 selectable.| –
Cell Qty:| Cells quantity in the battery.| –
Voltage Delta:| To set the highest and lowest voltage difference threshold between the cells during discharging.| √
Discharge Current:| Set the discharge current value.| –
Discharge Time:| Set the discharge test time.| √
Module Lower Limit:| The lower limit voltage of the battery.| √
Discharge Capacity:| Set the discharge capacity of the battery.| √
Cell Lower Limit:| Set the lower limit voltage of cells.| √
End Current:| When the voltage reaches the Module Lower Limit & the current reduces lower than the End Current will trigger the stop.| √

Note:

• Stop Threshold: The tester will automatically stop the test when one of the test conditions reaches the presetting value.
• For Discharge Capacity, Cell Lower Limit, and End current, please choose whether to use them as the stop threshold by turning the switch on or off.

1. Parameters Setting
   Users must fill in all parameters to create a new parameter set for the first use and press Save to save the settings. Then the system will automatically enter the Discharge Test Page. It supports modifying the parameters during the test process, and the final test parameters will be displayed on the Parameters Page directly when entering the discharge test next time.

2. Write-in Preset Parameters
   The system provides a parameter preset function. Users can write common test parameters into the Preset Parameter List and then select and read from the list before testing. 01. After filling in a set of parameters, press WRITE.
   02. Select Create on the pop-up box to set the parameter name, and the parameters will be saved in the Preset Parameters List. (Note: For the first use, the system will prompt to enter the parameter name directly, and no need to press Create to set.)
   03. Users can cover the preset record by pressing the file name and delete the preset parameter by pressing .

3. Read Preset Parameters
   Press the READ button. Select the preset parameters that have been saved in the pop-up box to read.

7.2.2 View Cell Data
After creating or reading the test parameters, press SAVE to enter the Discharge Test Page. Before testing, you can press MODIFY to double-check or modify test parameters.

The last step before starting discharge is to confirm the cable connection and cell data reading status. Users can check by viewing Cell Info to ensure that the system collects the data of the Module Voltage, Max Cell Volt, Min Cell Volt,
and voltage of each cell.
The test page offers multiple ways to view real-time data. Users can switch between Cell Info, Cell Voltage, and Module Voltage anytime during the test to view detailed data.
7.2.3 Discharge Test

1. Startup
   Close the DC breaker, press START, and observe the discharge current rising and stable at the setting value. It means the discharge test is running normally.

2. Modify Parameter
   Tt supports modification of test parameters during the test (ensuring that the stop thresholds are not triggered). Press MODIFY to change the test parameters, and press SAVE. The system will execute the new parameters to continue the test.

3. Pause/ Stop
   Users can press PAUSE/CONTINUE to control the test at any time.
   In addition, there are three methods to stop the test during the process:
   • Press the STOP icon on the screen;
   • Press the emergency button on the device panel;
   • Turn off the DC breaker directly.
   Note: When the discharge test is complete, turn off the device, disconnect the power cord, and remove the test cable. (Note: disconnect the test cable from the battery end first.)

7.3 Charge
It is a single charge test mode. Press the Charge icon on the Main Menu Page.
Users must select the input (charging power) before entering the Parameters Setting Page.

7.3.1 Parameters
The Parameters Setting Page will display the parameters of the last test.
Users can create, read and save the test parameters on this page.

–
Rated Capacity:| The nominal capacity of the battery.| –
Battery Type:| The type of tested battery, LiFePO4, Li(NiCoMn)O2, LiTiO, and LiMnO2 selectable.| –
Cell Qty:| Cells quantity in the battery.| –
Voltage Delta:| Set the highest and lowest voltage difference threshold between the cells during charging.| √
Target Voltage:| The target voltage of charging. The device starts to reduce the current at constant voltage when it reaches this value.| –
Overvoltage Protection:| The upper limit voltage of the battery.| √
Charge Current:| Set the max charging current according to the test requirements.| –
End Current:| When the voltage reaches the Target Voltage & the current reduces lower than the End  Current will trigger the stop.| √
Charge Time:| Set the test time.| √
Charge Capacity:| Set the charging capacity of the battery.| √
Cell Upper Limit:| Set the upper limit voltage of cells.| √

Note:
• Stop Threshold: The tester will automatically stop the test when one of the test conditions reaches the presetting value.
• For Charge Capacity and Cell Upper Limit, please choose whether to use them as the stop threshold by turning the switch on or off.

1. Parameters Setting
   Users must fill in all parameters to create a new parameter set for the first use and press Save to save the settings. Then the system will automatically enter the Charge Test Page. It supports modifying the parameters during the test
   process, and the final test parameters will be displayed directly when entering the charge test next time.

2. Write-in Preset Parameters
   The system provides a parameter preset function. Users can write common test parameters into the Preset Param List and then select and read from the list before testing. 01. After filling in a set of parameters, press WRITE.
   02. Select Create on the pop-up box to set the parameter name, and the parameters will be saved in the Preset Parameters List. (Note: For the first use, the system will prompt you to enter the parameter name directly, and no need to press Create to set.)
   03. Users can cover the preset record by pressing the file name and delete the preset parameter by pressing .

3. Read Preset Parameters
   Press the READ button. Select the preset parameters that have been saved in the pop-up box to read.

7.3.2 View Cell Data
After creating or reading the test parameters, press SAVE to enter the Charge Test Page. Before testing, you can press MODIFY to double-check or modify test parameters.

The last step before starting charge is to confirm the cable connection and cell data reading status. Users can check by viewing Cell Info to ensure that the system collects the data of the Module Voltage, Max Cell Volt, Min Cell Volt, and  voltage of each cell.
The test page offers multiple ways to view real-time data. Users can switch between Cell Info, Cell Voltage, and Module Voltage anytime during the test to view detailed data.
7.3.3 Charge Test

1. Startup
   Close the DC breaker, press START, and observe the charging current rising and stable at the setting value. It means the charging test is running normally.

2. Modify Parameter
   The device supports modification of test parameters during the test (ensuring that the stop thresholds are not triggered). Press MODIFY to change the test parameters, and press SAVE. The system will execute the new parameters to continue the test.

3. Pause/ Stop
   Users can press PAUSE/CONTINUE to control the test at any time.
   In addition, there are three methods to stop the test during the process:
   • Press the STOP icon on the screen;
   • Press the emergency button on the device panel;
   • Turn off the DC breaker directly.
   Note: When the charge test is complete, turn off the device, disconnect the power cord, and remove the test cable. (Note: disconnect the test cable from the battery end first.)

7.4 Data
The system supports automatic data saving during all testing processes. Press Data on The Main Menu Page to enter the Data Page, and users can check, delete, and download data on the page after testing. On the left side of the page is a list of all data. Press the data name and the corresponding data information will be displayed on the right side of the page.

There are three functions that users can operate on the page:

1. EXPORT IMAGE
   It is used for exporting screenshots. Insert the USB disk into the USB port of the tester, press the EXPORT IMAGE, and select USB to export.

2. DELETE
   Check or Select all saved data, and press DELETE to complete the deletion.

3. EXPORT
   Check or Select all saved data, and press EXPORT to download the corresponding data to the USB disk.

Repair & Maintenance

1. The warranty period of the main tester is one year from the date of receipt, and the warranty does not cover artificial damage.
2. The manufacturer provides free repair during the defects liability period and technical consulting services for a lifetime. If you have any technical problems or advice, please get in touch with us.
3. When the voltage and current accuracy of the equipment are over the range of technical specifications, please contact the manufacturer for accuracy calibration.
4. When the equipment is stored for a long time, there may be dust and other dirt on the mesh cover of the heat outlet, which needs to be cleaned regularly. If you find that the fan does not work when you start the equipment after a  prolonged storage period. Please stop the unit, remove the net cooling cover, dust the fan, and brush the lubricant.

Transportation & Storage

1. The tester is equipped with a particular carry case and transported in a carton, which is shock-resistant and reliable.
2. Storage conditions: placed in a dry equipment storage room, temperature: -20~70°C , humidity: <90%.

Environmental Statement

1. The tester uses a transport carton which is a recyclable material.
2. The main machine and other components are non-polluting sources.

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