AUTEL MaxiEV BCE100 Lithium Battery Balancer User Manual

AUTEL MaxiEV BCE100 Lithium Battery Balancer

FAQ

Frequently Asked Questions

• Q: Can the MaxiEV BCE100 Lithium Battery Balancer be used with batteries of different voltage levels?
  • A: Yes, the balancer is suitable for cell balancing of li-ion battery modules/packs with different voltage levels on the market.
• Q: How does the device ensure safety during the testing process?
  • A: The device has multiple protections and will automatically terminate the test if any abnormal conditions are detected. It also provides warnings through LCD prompts and beeps to assist users in handling such situations.

OVERVIEW

MaxiEV BCE100 Lithium Battery Balancer is developed to solve cell voltage imbalance quickly. Avoid the impact of overcharge and over-discharge on the battery caused by the unbalanced voltage of the cell, and eliminate the capacitydeviation caused by self-discharge and inconsistent Coulomb efficiency.

With high precision, fast maintenance, safety and reliability, and a wide range of applications, it significantly improves the consistency of the battery pack and increases the battery’s service life. It supports creating any voltage difference between cells to simulate the battery’s performance under harsh working conditions, which is suitable for R&D experiments.

Features

• Wide application: has a wide voltage range and is suitable for cell balancing of li-ion battery modules/packs with different voltage levels on the market.
• Flexible working mode: charging, discharging, and balancing modes are free to select for convenient testing.
• Battery balancing: fully activate lithium battery performance.
• Independent channel design: cells testing in separate channels, users can freely select the cell in the module/pack to be tested.
• Voltage clamped: constant voltage and reduces current, ensure that the voltage of the cells in the battery is infinitely close to the target voltage to improve the equalization effect.
• Multiple protections: It supports providing various test thresholds and adequate protection for different 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.
• Customized test harness: supports multi-types of port pin definition of battery for bridging transit testing.
• Ample space internal memory: supports uninterrupted auto data storage during the test to avoid data loss when accidental power is down.
• Remote system upgrade: convenient for new function upgrades and device failure location by remoting.
• Expandable functions: reserved extend port for function expansion.
• Calibration correction: the voltage and current values measured by the device can be calibrated and corrected at any time to ensure measurement accuracy.

Main Functions

• It is mainly used for battery cell charging, discharging, and balancing maintenance, which is suitable for the voltage level of the battery module.

System Component Unit

• MaxiEV BCE100 configures with the main unit, cell acquisition kit, temp acquisition wire, AC power cord, USB disk, 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, charge unit, equalization unit, and panel operating unit.

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.

Device Safety

• The device is equipped with multiple protections, including reverse connection, overvoltage, overcurrent, overtemperature, and communication security.

Safety Precautions

Operator Requirements

Alarm

1. Operators are required to receive training related to the use before operating.
2. Before operating, operators should read the user manual and the related regulations.

Operating Environment

Alarm

1. Operating temperature: -5~50°C
2. Relative humidity: 0~90% (40±2°C), rainy-day outdoor use is prohibited.
3. Non-corrosive, explosive, and destructive insulation gases and conductive dust of the test environment are required.
4. Ensure ventilation of the operating environment.

Connection Precaution

Alarm

1. Ensure the unit’s AC input switch stays off before connecting the cables.
2. Please strictly follow the instructions to connect the cables properly.

Danger

1. Warning signs need to be placed in the test work area to avoid the risk of tripping over the cable.
2. 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.

Operating Precautions

• The operation of the device is by touching the screen input. Please follow the screen prompts.

Danger

• The working power of this device is AC input. Please make sure the operating power is reliably grounded.

Common Misoperation

1. Operating tools are not insulated.
2. Operating the device without following the user manual.

Possible Damage Caused by Misoperation

1. The operating tool is not insulated. The positive and negative poles of the battery pack are too close to cause a short circuit accident.
2. The test will not commence if the device is not operated properly.

Emergency Treatments on Abnormal Conditions

• Disconnect the unit’s operating power and test cables.

Precaution of Special Conditions

• If the operator does not make insulation measures or causes a short circuit due to improper operation, disconnect the cable in time.

Other Safety Warnings

• Strictly observe safe operating practices and correct operation methods.

Main Technical Parameter

Installation

• It is a portable device and does not involve installation.

Device Description

Panel Description

__

4

| EXTEND| extend port;

reversed for communication expansion

5| AC INPUT| 100~264Vac single-phase three-wire input
6| AC Power Switch| device power switch
7| Antenna| To enhance the received signal
__

8

| BATTERY 1# Equalization Unit Port| 16pin, 1# unit equalization harness socket,

max 12cells per unit

__

9

| BATTERY 1# Temp Acquisition Port| 24pin, 1# unit temperature acquisition port

(optional function)

__

10

| BATTERY 2# Temp Acquisition Port| 24pin, 2# unit temperature acquisition port

(optional function)

__

11

| BATTERY 2# Equalization Unit Port| 16pin, 2# unit equalization harness socket,

max 12cells per unit

Pin Definition

Equalization Port (16Pin)

Temperature Port (24Pin)

Cable Description

The following is an introduction to the test harnesses.

• Equalization Bus-harness
  • For the cell equalization test; connect with the device end and subharness end.
• Equalization Sub-harness ( Clips-type)
  • For the cell equalization test; connect with cell ends follow clip marks and clip in order from B1-, B1+, B2+, …, and B12+ with the cell poles.
• Temp Acquisition Wire
  • For temperature data collecting; connect with the Temp Acquisition Port of the tester and the battery.
• AC Power Cord
  • 100~264Vac single-phase three-wire/max 10A.
  • Frequency: 45~65Hz.

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.

Connecting Diagram

Please do not switch on the device before connecting!

Cables Connect Order:

1. Connect the bus-harness to the device end first;
2. Connect the sub-harness to the battery end;
3. Connect the bus-harness and the sub-harness terminals;
4. Connect the AC power cord to the battery end and the power supply.

Equalization Harness Connection

Here is a connecting diagram for reference.

Connecting Order:

1. Plug equalization bus-harness to device 1# Equalization Unit Port.
2. Clip equalization sub-harness to cell poles from B1-, B1+…B12+ of the Battery 1#.
3. Connect the bus-harness and the sub-harness terminals.

Follow the steps above to connect the 2# Equalization Unit Port with the Battery 2#.

AC Input Connection

• Connect the AC power cord with the AC INPUT of the tester and the power supply.

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 the connecting is fastened after joining.

Operating Instruction

• After the device connection, turn on the AC Power Switch to start the tester.
• The screen will display the Welcome Page, and then automatically jump to the Main Menu Page, including Balancing and Maintenance, Data Analysis, Data Dump, and Settings function icons.

Settings

• Press the Settings icon on the Main Menu Page to set and modify system parameters. It has nine sub-pages: Units, Language, Data Storage Intervals, Temperature Protection, Cell Count, Wi-Fi, Log Management, Device Maintenance, and About.

Units

• The tester provides different units of measurement for users to select by actual needs: Metric or Imperial, Battery Capacity (Ah) or Energy (Wh).

Language

• The system language supports English, Simplified Chinese, and Traditional Chinese. Users can switch according to their needs, and then the tester will automatically reload the system.

Status Color

• It is the function to set a different color for each test state to make all processes more intuitive for users. Users can modify colors based on their needs. Please notice to press OK to save the settings.

Data Storage Intervals

• It is for data saving interval; please set it as needed.
• The tester is equipped with a data storage function, which saves cell voltage, string voltage, test current, and other test data during tests.

Temperature Protection

• The device provides temperature protection for the various types of batteries.
• If the device detects that the battery temperature exceeds the preset values during the test, the LCD prompts an alarm and the test stops. The default battery temperature protection is 10~70°C. Users can modify it if needed

Cell Count

• It supports setting battery cell quantity to meet different testing application scenarios. It can test max 24 cells simultaneously and has two options, “1 module (24 cells in each module)” and “2 modules (12 cells in each module)”.
• Please select by actual.

Wi-Fi

• It is for device networking. Install the antenna on the device, then choose a network to connect for remote online system update.

Log Management

• The running log is used for exception analysis by manufacturers. There is no need for the user to operate. Contact the manufacturer for guidance when the device is abnormal

Device Maintenance

• It is mainly used for factory calibration and commissioning. Generally, users do not need to modify settings. A password is required to enter the page, please contact the manufacturer if necessary.
• This manual will introduce functions of Current app version, Module upgrade, and Date and time.

Current App Version

• This item is used for local updates of the device operating system. Insert a USB disk with the updating program into the USB port of the tester.
• Please note to name the program update.apk and put it in the root directory. Press Current app version and select the upgrade program to complete the updating.

Module Update

• This item is for local/online software updates of the device firmware modules.

Local Update

Version update is for the local upgrades. Insert a USB disk with the updating program into the USB port of the tester. Please note to name the program Unit.bin and put it in the root directory. Check/Select All firmware modules that need to be updated, press Version Update, and select the updating program to complete the upgrades.

Online Update

• Users need to confirm an available upgrade file with the manufacturer and send the Device ID to us.
• Then connect the device to an available Wi-Fi and press Read Version first, then press Online Update. The system will auto-receive the updating package.

Date and Time

• This is for system date and time calibration. Please set it by actual.

About

• It shows the device info about the Current version of the system, Device ID, and Equipment model, and users can operate the online updating on the page through the Check for updates icon.

Equalization

Please go back to the Main Menu Page after confirming the Settings. Press the Balancing and Maintenance icon to enter the Test Page. The equalization function supports Charging, Discharging, and balancing Mode.

1. Test State
   • This area displays the test status of each module. (If “Not connected” or “Error” is displayed, please check the battery connection status.)
2. Parameter Settings
   • The function icon is for presetting or modifying test parameters.
3. Details
   • This function displays the details of real-time test data, including cell voltage, current, capacity, and cell test status.
4. Cell Volt Histogram
   • This area displays the real-time cell voltage of each cell in a diagram format.
5. Device Information
   • This area displays the real-time data of test start time and working hours.
   • The preset parameters of the working mode and operating current are also shown.
6. Module Information
   • This area displays the real-time data of the tested module.
7. Operating Item
   • Start/Pause/Continue/Stop buttons for control of the test.

Parameter Settings

• Respectively pressing the Module 1# and Module 2# to set the test parameters.
• Press in the upper right corner to enter the Parameter Settings Page.
• Please remember to press the Save icon to save the setting.

Starting Test

• Check the battery connection status and confirm whether the cell information is collected.
• Press Start on the Test Page and confirm in the pop-up box to start the test.

The real-time battery status info will be displayed on the testing page during the test.

• If you want to double-check or modify test parameters, press and return to the Parameter Settings Page.
• The overview of the real-time test data will be displayed on the Test Page.

Device information
Start time:| The test start time.
Working hours:| The test duration.
Working mode:| The test mode (preset in parameter settings).
Operating current:| The test current (preset in parameter settings).
Module information
Battery type:| The battery type (preset in parameter settings).

• Users can press Details on the Test Page to view the real-time cell voltage, current, capacity, and status during the test.
• Users can press the Histogram on the Test Page to view the real-time cell voltage, current, capacity, and status during the test.
• After starting the test, users can select Pause, Continue, or Stop the test at any time by pressing the corresponding buttons on the bottom of the Test Page.
• The system will automatically stop the test when the test conditions trigger device protection.

Complete Condition

Note

• For the charge/balancing test, when the cell voltage reaches the Voltage threshold, the test current is less than 0.2A, and the working hours is greater than 2 minutes, the cell status is displayed as Complete in Device Details, indicating that this cell test is completed.
• For the discharge test, when the cell voltage reaches the Voltage threshold, the test current is less than 0.2A, and the working hours is greater than 3 minutes, the cell status is displayed as Complete in Device Details, indicating that this cell test is completed.
• When the status of each cell shows Complete, the module test is complete.

Data Analysis

The tester supports the data analysis function and provides a histogram/curve format for viewing. Press Data Analysis to enter the page, double-click the data you want to view and switch Histogram/Curve to view data variation charts. Press the icon in the upper right corner to check the overview of the data.

Data Dump

This function is used for data deletion and download. Press Data Dump to enter the Data Dump Page.

1. Delete
   • Select the data you want to delete or choose Select all, and press Delete to confirm the deletion.
2. Dump
   • Insert the USB disk into the device’s USB port, select the data you want to export or choose Select all, and press Dump to USB to export data to the USBdisk.

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 get in touch with 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.

Transportation & Storage

1. The tester is equipped with a particular carry case and transported in a carton, which is shock-resistant and reliable in transportation.
2. Storage conditions: placed in a dry equipment storage room, storage 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.

FCC STATEMENT

This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions:

1. this device may not cause harmful interference
2. this device must accept any interference received, including interference that may cause undesired operation.

Any changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception,which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.

RF Exposure

• This device complies with FCC radiation exposure limits set forth for an uncontrolled environment.
• This equipment should be installed and opera ted with minimum distance 20cm between the radiator & your body.

ISED Statement

This device contains licence-exempt transmitter(s)/receiver(s) that comply with Innovation, Science and Economic Development Canada’s licence-exempt RSS(s).
Operation is subject to the following two conditions:

1. This device may not cause interference.
2. This device must accept any interference, including interference that may cause undesired operation of the device.

The digital apparatus complies with Canadian CAN ICES-3 (B)/NMB-3(B).

This device meets the exemption from the routine evaluation limits in section 2.5 of RSS 102 and compliance with RSS 102 RF exposure, users can obtain Canadian information on RF exposure and compliance.
This equipment complies with Canada radiation exposure limits set forth for an uncontrolled environment.

This equipment should be installed and operated with minimum distance 20cm between the radiator & your body.

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