AUTEL BCE100 EV Battery Pack Cell Balancer User Manual

AUTEL BCE100 EV Battery Pack Cell Balancer

USER MANUAL

MODEL: BCE100

1. 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 capacity deviation 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.

1.1 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.

1.2 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.

1.3 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.

1.4 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.

1.5 Device Safety

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

2. Safety Precautions

2.1 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.

2.2 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.

2.3 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.

2.4 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.

2.5 Common Misoperation

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

2.6 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.

2.7 Emergency Treatments on Abnormal Conditions

Disconnect the unit’s operating power and test cables.

2.8 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.

2.9 Other Safety Warnings

Strictly observe safe operating practices and correct operation methods.

3. Main Technical Parameter

4. Installation

It is a portable device and does not involve installation.

5. Device Description

5.1 Panel Description

5.2 Pin Definition

5.2.1 Equalization Port (16Pin)

5.2.2 Temperature Port (24Pin)

5.3 Cable Description

There are mainly 3 types of cables for MaxiEV BCE100: Equalization Bus- harness,
Equalization Sub-harness, and AC Power Supply Cables.

Note:

⚫ Please refer to the provided image for reference. Actual product details may vary slightly.
⚫ The standard unit will be equipped with one kind of equalization sub- harness. 1) and 3) need to be customized.
⚫ 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.

6. 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.

6.1 Equalization Harness Connection

Here is the connecting diagram for different types of equalization subharnesses:

6.1.1 Low-voltage Connector-type Sub-harness

Connecting Order:

Plug the equalization bus-harness to device 1# Equalization Unit Port.
Connect the equalization sub-harness to low-voltage interface of Battery 1#.
Connect the bus-harness and the sub-harness terminals.
Follow the steps above to connect the 2# Equalization Unit Port with the Battery 2#.

Connecting Order:
Plug the equalization bus-harness to device 1# Equalization Unit Port.
Clip the equalization sub-harness to cell poles from B1-, B1+…B12+ of the Battery 1#.
Connect the bus-harness and the sub-harness terminals.
Follow the steps above to connect the 2# Equalization Unit Port with the Battery 2#.

6.1.3 Customized Fixture Sub-harness
A customized fixture is supported for connection. The connection diagram is referenced below, and the actual connection is subject to the customized fixture.

6.2 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.

7. 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.

7.1 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.

7.1.1 Units
The tester provides different units of measurement for users to select by actual needs: Metric or Imperial, Battery Capacity (Ah) or Energy (Wh).
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7.1.2 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.

7.1.3 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.

7.1.4 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.

7.1.5 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
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7.1.6 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.

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

7.1.8 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

7.1.9 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.

7.1.8.1 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.

7.1.8.2 Module Update
This item is for local/online software updates of the device firmware modules.

1) 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 update, press Version Update, and select the updating program to complete the upgrades.

2) 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.

7.1.8.3 Date and Time
This is for system date and time calibration. Please set it by actual.

7.1.10 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.
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7.2 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

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.

7.2.1 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.

7.2.2 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.

• 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.

7.2.3 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.

7.3 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.

7.4 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 USB disk.

8. 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.

9. 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%.

10. 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.

Specifications

• Product Name: MaxiEV BCE100 Lithium Battery Balancer

• Application: Cell voltage balancing for li-ion battery modules/packs

• Features:

  • Wide voltage range for various battery levels

  • Flexible working modes: charging, discharging, and
    balancing

  • Independent channel design for testing cells separately

  • Voltage clamped for precise equalization

  • Multiple protections for safety

  • Intelligent operating system with user-friendly interface

  • Supports custom test harness and internal memory storage

FAQ

Q: What is the main purpose of MaxiEV BCE100 Lithium Battery Balancer?

A: The main purpose is to quickly solve cell voltage imbalances in lithium batteries, improving battery consistency and lifespan.

Q: What protections are offered by the product during testing?

A: The product offers multiple protections and triggers automatic termination of tests in case of abnormal conditions, with LCD prompts and beeping warnings for user assistance.

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