Battery Capacity Tester User`s Manual SBS-8400
Contents
1. CapaSum the total capacity discharged To browse all cells voltages EEE PEE E ore Table amp Chart screens TestTime the time since the discharge started process of discharging all changes aei are similar with the one in BattLow the quantity of the batteries in which voltage is can be activated immediately already below the BattLowV you set BatteryView MaxBatt V the highest voltage battery in the group MinBatt V the lowest voltage battery in the group Page 19 30 SBS 8400 USER MANUAL 74 nn TESTY FRIM 4 8 6 Press Param to adjust the parameters during the discharge if necessary all changes can be activated immediately and the discharge will not be stopped 4 8 7 SysState in the discharge interface will help you know the status of the discharge 4 9 Download Data to PC 4 9 1 SBS 8400 provides two methods to record the test data a Use the RS232 cable to connect the unit with the PC Through the analysis software real time test data can be displayed and downloaded during the test b Internal memory always saves all testing data you can download the data via USB disk or RS232 cable to a PC 4 9 2 Press Data in the main menu to enter the data interface DataFile 01 04 2014 01 02 18 00 2014 01 03 12 00 2014 01 04 18 00 Test time amp date Up If the data files are more than 1 page use Up Down to brow2. 4 5 Starting Up and Input Operation 4 5 1 After the SBS 8400 has been connected to the battery system turn on the AC power switch 4 5 2 A welcome interface will appear where you can see the unit identification Press anywhere on the screen to go to the main menu If 10 seconds elapse the system will jump to the main menu automatically Page 16 30 iM il A SBS 8400 USER MANUAL 4 5 3 SBS 8400 input method touchpad directly on LCD screen SBS 8400 v27 SBS 8400 DZA Charge SMART BATTERY CAPACITY TESTER Data Setup BatteryView Preset STORAGE BATTERY SYSTEM LLC 4 6 Check the Connection of the Wireless Modules 4 6 1 Press BatteryView on the main menu to enter the table interface if all wireless modules are connected correctly you will see the voltage of each cell If the voltages of some cells are not showing please re check the wireless module connections Min 020 02 036V Min 020 02 036V The highest amp lowest voltage cell in battery string 001 02 180V 003 02 180V 004 02 180V 005 02 180V 006 02 180V 007 02 180V 008 02 180V Group 1 Next 009 02 182V 010 02 182V 011 02 182V 012 02 182V 013 02 182V 014 02 182V 015 02 182V 016 02 182V 017 02 186V 018 02 186V 019 02 186V 020 02 036V 021 02 186V 022 02 126V 023 02 186V 024 02 186V OOS O10 0154 0204 Prev LEISG Each screen can show 24 cells Back to the main me
3. SBS PANIER IES E SBS 8400 BATTERY CAPACITY TESTER USER MANUAL Rev 2 1 12 14 STORAGE BATTERY SYSTEMS LLC N56W16665 Ridgewood Dr Menomonee Falls WI 53051 Phone 800 554 2243 Fax 262 703 3073 Website www sbsbattery com A SBS 8400 USER MANUAL FS Ene eee Contents 1 Introduction 1 1 Features 1 2 System Components 2 Main Technical Parameter 2 1 Environment amp Conditions for Use 2 2 Structure amp Weight 2 3 Working Power Supply 2 4 Input Voltage from Battery strings 2 5 Discharge Current Range 2 6 Parameter Display amp Measure Accuracy 2 7 Protection amp Warning 2 8 Data Management amp Communication 3 Basic Operational Principle 3 1 Battery Testing Principle 3 2 Constant Current Principle 4 Operating Instructions 4 1 Environments Requirement 4 2 Panel Description 4 3 Main Machine Connection 4 4 Wireless Modules Connection 4 5 Starting Up and Input Operation 4 6 Check the Connection of the Wireless Modules 4 7 The Preset Function 4 8 Discharge 4 9 Download the Data to PC 4 10 System Setup 4 10 7 Calibration 4 11 Charge Monitoring Function 4 12 Multiple units in parallel 5 PC Software Instruction 5 1 Main Functions 5 2 Install Analysis Software to PC 5 3 Real Time Recording During the Testing 5 4 Download Data File from USB Disk 5 5 Generate Excel Test Report 6 Precautions 7 After Sale Service SBS SBS 8400 USER MANUAL E ikl e A 1 Int
4. gt NO K Wireless module NO 4K 1 NO 4K 2 NO 4K 3 NO 4K 4 4 4 3 1 Read the module number from the label the modules find the correct cells to connect the module to Do not connect the modules to 4 batteries which are not in series like NO 1 5 8 9 the misconnection will likely damage the module immediately 4 4 3 2 Use the alligator clips 4 red 1 black to connect modules to the batteries please follow the correct wiring rule Red 1 to Red 4 from long to short and the wiring diagram printed on the label of the modules 4 4 4 Connection guide when cell quantity is not a multiple of 4 4 4 4 1 SBS 2 6 12 wiring for last 4 to 1 cells Page 13 30 A SBS 8400 USER MANUAL 4 yellow wires from left to right from long to short means this wire is not connected separates the groups of cells Page 14 30 74 SBS 8400 USER MANUAL nh TESTO eres 4 4 4 2 SBS 1 2 2 wiring for last 4 to 1 cells 4Ared wires from left to right from long to short means this wire no need to connect separate the last cells with other cells Last four 1 2V 2V cell Last three 1 2V 2V cell Module Module Module Kla 4 4 5 Spare modules and reassigning module numbers 4 4 5 1 No O spare modules With each module set you will find No O spare modules They have the following label No number assigned They can be addressed to any module No and allow testing to continue if i A any assigned mod
5. Auto scan and display of the voltage data for each battery during the discharge Graphical histograms display the status of each cell throughout the discharge and the use of different colors to highlight the lowest and the highest voltage can simplify the identification of possible problems 5 7 inch colorful touching LCD screen The large touchscreen allows menu selection and programming and shows all parameters and the voltage histogram during the discharging process Intelligent judgment program SBS 8400 continuously monitors voltages and regulates test progress to shutdown parameters Automatic adjustment of discharge current level allows this revolutionary program to keep the test stable and smooth Presetting function for discharge parameters SBS 8400 provides 30 presets for setting up discharge parameters in advance this design can simplify the programming operation and speed up testing Real Time PC Logging Powerful software for downloading real time data or use the USB port to download the data after the discharging process PC analysis software assists users in analysis of the data and creation of test reports 8M internal memory SBS 8400 s internal memory can record several sets of test result data independently and the menu interface provides basic management operations like reviewing analyzing or deleting test results The Advantages Features of SBS 8400 Analysis Software a b c d e Allows data do
6. a SBS S series DC load bank 3 Basic Operational Principles 3 1 Battery Testing Principle Because of the differences in materials construction craftsmanship installation environments and maintenance practices battery strings from different manufacturers have many unique characteristics Even the same types of batteries from the same manufacturers will see variances in performance and capacity from one string to another There are many ways to predict the condition of a battery systems performance and remaining life expectancy however the IEEE capacity testing procedures are the only definitive proof of a battery systems ability to perform as specified by the battery manufacturer Nowadays with the popularity of VRLA batteries fewer indications are available to determine the condition of a battery We believe a The battery voltage in float charge operation and the batteries true capacity have no direct correlation As we know batteries which have a low capacity can still display a normal voltage in float mode Simple interpretation of available data is not accurate in determining if a battery will perform as required when called upon b Full rated capacity discharging is still the most accurate method to test the performance of batteries For systems which are created by a number of cells connected in series the actual capacity of battery string relies on the ability of the worst cell to perform to capacity The principle goal
7. of capacity testing is to find these poorly performing cells and replace them to increase the service life and reliability of the whole battery system Applying a constant current as specified by the manufacturer for a specific period of time allows for monitoring the batteries voltage to ensure the cell remains above Page 7 30 SBS E Al A SBS 8400 USER MANUAL the specified cut off voltage and allows us to determine the battery and systems actual performance capacity as a way of ensuring the systems performance Examining a voltage drop curve for the discharge rates iic O50 4 00 U f From the curves we know what the performance is supposed to be at a given rate of discharge and this is the most uniform and accurate method for estimating the capacity of a battery 3 2 Constant Current Principle The internal circuitry of the SBS 8400 uses a PWM pulse width modulation control technique Controlled by the CPU and sensing circuits the power circuit can discharge the battery string with very accurate automatically corrected control Data collection and interpretation by the software is automatic and accurate Page 8 30 VAS SBS 8400 USER MANUAL nt TESTY eee 4 Operating Instructions 4 1 Environment Requirement The unit should only be used in environments that are free from dust and flammable or explosive gases It should be properly ventilated to dissipate heat produced 4 2 Panel Description A
8. BattLow qty of cells which voltages below BattLowV ACError the reaction for AC To change Parameter number power losing for SBS 8400 Param 1 Param 2 Param 3 a i Press Modify to locate the preset parameters This item will lock at Stop n auan need to be changed to change value Strings number of strings in Cancel to quit After all setting press Apply parallel being tested at once to save 4 7 2 TestCapa TestTime BattLowV GrpLowV are the test stop conditions if any of these set points is reached the discharge will stop automatically 4 7 3 For 1 battery string discharge please keep Strings at 001G if parallel discharging 2 4 strings is needed 2 4 times the wireless modules will be needed The discharge current will be for each string being tested 4 7 4 If you want the discharge to stop when one bad cell reaches the BattLowV please keep Battlow in 001 If you want the discharging to stop when N bad cells reach the BattLowV you can set the BattLow to the number you need 4 7 5 If you are not utilizing the wireless modules for the discharge please set the BattSum to 000 BattLowV will be disabled from terminating the discharge Page 18 30 74 SBS 8400 USER MANUAL RATIER TESTY eres 4 8 Discharge 4 8 1 Press Discharge on the main menu to enter the discharge paramete
9. cells monitoring data monitoring unit SBS 8400 Battery discharge amp capacity tester auxiliary power unit PC analysis software ue power consumption wireless signal nit receiver panel operation unit 2 Technical Parameters 2 1 Environment amp Conditions for Use 2 1 1 Operating temperature 20 F 122 F 5 c 50 c full power forced air cooling 2 1 2 Storage temperature 40 F 150 F 40 70 2 1 3 Relative humidity lt 90 105 F 5 F 40c 2 c 2 1 4 Altitude limit 0 2000m 20 F 122 F 5c 50c full power 2000m 4000m 20 F 90 F 5 c 30 c full power 90 F 122 F 30 c 50 c 80 of ratings 2 2 Structure amp Weight Dimensions length width height SBS 8400 26 4 x 9 05 x 14 6 670mm x 230mm x 370mm Page 5 30 VAS SBS 8400 USER MANUAL SM il A Weight SBS 8400 52 9 Ibs 24 kg main tester only 2 3 Working Power Supply SBS 8400 AC 120V single phase 45Hz 65Hz 220VAC optional 2 4 Input Voltage from Battery String SBS 8400 10 300V 2 5 Discharge Current Range Voltage range Current range 10 15V 0 60 A 15V 60V 0 120 A 86 150V 0 120 A 190 280V 0 60 A 2 6 Display amp Measurement Accuracy LCD Display 5 7 inch LCD color touch screen Displayed discharge current resolution 0 1A accuracys 0 5 Displayed battery strings voltage resolution 0 1V accuracys 0 5 Displayed cells voltage 1 2V 2V 6V cells resolution 0 001V accu
10. ell _ _ __ gt NO 2 Wireless module NO 5 NO 7 NO 8 b ll Cell Ce e Cell Cell _ _ gt NO K Wireless module NO 4K 1 NO 4K 2 T MOJI A Cc MOJIPA MOJ PA V MOJ PA l NO 4K 3 NO 4K 4 4 4 2 Read the module number from the label the modules find the correct cells to connect the module to Do not connect the modules to 4 batteries which are not in series like NO 1 5 8 9 misconnection will likely damage the module immediately 4 4 2 1 Use the alligator clips 1 red 1 black 4 yellow to connect modules to the batteries please follow the correct wiring rule Yellow 1 to Yellow 4 from long to short and the wiring diagram also print on the label of the modules Page 12 30 5S SBS 8400 USER MANUAL RATIER TESTY FRYE MEN Wiring Diagram 4 4 3 SBS 1 2 2 wireless modules for 1 2V 2V connection SBS SBS 1 2 2 Wireless module STORAGE BATTERY SYSTEMS INC Module No 01 Battery No 001 004 Wireless module number and the battery to connect A JJ g2 g2 ro Q Q O m N Ww For example NO 1 module Connect to cells NO 1 NO 4 from positive Red 4 NO 2 module Connect to cells NO 5 NO 8 from positive NO 3 module Connect to cells NO 9 NO 12 from positive 7 i me 7 NO 1 Wireless module 1 NO 1 Wirel NO 1 NO 2 NO 3 NO 4 oe Cell Cell e Cell Cell D gt NO 2 Wireless module NO 5 NO 6 NO 7 NO 8 Il ll Ce Ee Cell Cell lt
11. ess receiver for working with different frequency wireless modules Same frequency in same room gt gt Interference Different frequency in same room gt gt No interference Module gt gt FM 1 Module gt gt FM 1 Module gt gt FM 1 Module gt gt FM 2 SBS 8400 gt gt FM 1 SBS 8400 gt gt FM 1 SBS 8400 gt gt FM 1 SBS 8400 gt gt FM 2 4 10 6 SBS 8400 can use three different ranges of external current clamps 100 200 600A Please select the correct clamp type when you connect an external clamp to the SBS 8400 An external clamp is needed when a Two SBS 8400 or SBS 8400 SBS S load banks are operated in parallel external clamp will measure the external unit current and add it to the primary SBS 8400 b SBS 8400 is used in charge monitoring mode the external clamp will measure current from charger to the battery string and calculate the total Ah charged Page 22 30 74 SBS 8400 USER MANUAL ner TESTY FRENN 4 10 7 SBS 8400 provides a calibration function if you have a high accuracy multi meter and Ammeter you can calibrate the unit by yourself Change the date to 2099 12 year month the Cal button will be activated Press Cal to enter the calibration interface GroupVol calibrate the Calibrate Press Cal to select the parameters need to be voltage of battery string Function 4 11 1 Although the SBS 8400 can t charge the battery string it provides a charge monitoring function
12. ffers 100A SBS 8400 will offer 100A if SBS S offers 80A SBS 8400 will offer 120A Page 24 30 SBS 8400 USER MANUAL SBS c If any stop threshold is reached on the SBS 8400 all SBS S unit s will receive a control signal to terminate the discharge at the same time 4 12 2 Two SBS 8400 in parallel 4 12 2 1 Connections a Connect SBS 8400 s with battery string by power cables b Connect external current clamp with master SBS 8400 DC CURRENT MEASUREMENT port and put clamp on the negative cable from the parallel SBS 8400 to battery string SBS 8400 as master unit SBS 8400 as parallel unit Battery String 4 12 2 2 Setting a Select the correct clamp range in master SBS 8400 setup interface b Set all 4 stop thresholds and other parameters on both SBS 8400 parameter interfaces and set the total discharge current to TestCurr on the master SBS 8400 c Set TestCurr to the max value that the parallel SBS 8400 can offer 4 12 2 3 Discharge a Start discharge on both SBS 8400 units the parallel SBS 8400 will discharge the current on the unit b External clamp will add discharge current from parallel SBS 8400 to master SBS 8400 And master SBS 8400 will regulate the proper current to keep the total current set For example 200A in total if parallel SBS 8400 offers 100A master SBS 8400 will offer 100A if parallel SBS 8400 offers 80A master SBS 8400 will offer 120A c If any stop thresh
13. ime interval during the discharge e Cell voltage each battery voltage can be displayed by bar chart The bar chart can show you the initial and end voltages Using the scroll bar on the top of this window you can locate any time in testing to see the relevant result PF Cell Voltage aniisi 5 5 Generate Excel Test Report 5 5 1 Press the amp icon to generate a report and in the system information window it will show you the total pages in the report choose No to generate an Excel report which includes all data information If you don t need a report with so many pages press Yes to select a compression and generate an Excel report which has the number of pages you want SBS 8400 Manager File Realtime Monitoring Optic a ewe File List System Information Generate an Excel report which has Generate an Excel report the number of pages you want including all data Page 29 30 SBS SBS 8400 USER MANUAL i il A 5 5 2 The compress report interface input the number of pages you want and press compress report to decrease the total page numbers and press Export Report to save the Excel report The page No before compressing 18 Compress report to page 18 Generates an Excel report which has the number of pages you want Back to main interface l Compress Recover all pages of the data file ee oo E Undo Compress 6 Precaution
14. ir cooling fans External current measurement Wired modules input Alligator clip 4 yellow 1 red 1 black Communication light red Wireless module for 2V 6V 12V SBS 2612 Page 9 30 VAS nt TESTY FRYE MEN SBS 8400 USER MANUAL Power light green Alligator clip 4 red 1 black a Communication light red Wireless module for 1 2V 2V SBS 12612 4 3 Main Machine Connections 120V AC 60Hz Power Source 220V AC 50Hz Power Source Optional DC Breaker Power Cable black Power Cable red Battery String 4 3 1 Use the power cables 1 red 1 black to connect the SBS 8400 to the battery string to be tested 4 3 2 Use the power supply cord to provide the SBS 8400 with an AC power source a The SBS 8400 supports 120V AC 50Hz 60Hz external AC input power b If your power source is 220V AC 50Hz 60Hz please use the optional 220V AC to 110V AC transformer to power the unit or inform us when you plan to order a SBS 8400 and unit will be shipped to support 220V AC Page 10 30 YAS nt TESTY FRE MEN SBS 8400 USER MANUAL 4 4 Wireless Modules Connections Before connecting the wireless modules please install the antenna Wiring Diagram 4 4 1 SBS 2612 wireless modules for 2V connections SBS 2 6 12 Wireless Module Module No 01 5c ery N 001 004 Black Wireless module number and the battery to connect For example NO 1 module C
15. llLowQty 1 1 TestCapa 6814H of Batteries String Ambient Start Temp F 24 Tr 2 Data Analysis 4 Load Data by R5232 Cell Voltage v Test DateTime 2 0 4 19 2010 9 53 41 PM Main Interface a SBS 8400 Manager ne 4 File Realtime Monitoring Option Window Help nell Asm 4 3am File List tgo 0634 fbotmp1 fgdf ay 1 f Current Curve sel Cell Curve en Battery Capacit 7 Petual 881AH BI 44 1 J fy GS Exit Ctrl E f Strina Voltage Time HMSYoltage YCurrent A Capacity 1 Y 0 00 00 0 00 06 0 00 12 0 00 18 0 00 24 0 00 30 0 00 36 0 00 42 0 00 48 0 00 54 C Users Yi De 5 4 3 In the main interface you will see 6 windows which show all necessary testing information Page 28 30 VAS SBS 8400 USER MANUAL nt TESTY FRE MEN a Total current curve the current during the discharging the value is negative during discharging and positive in charge monitoring mode b Cell curve the voltage curve of each cell battery can be added and deleted by a right click menu f Cell Curve Select the displayed cell curve Input the battery number range From Cell No To Cell No Hide Title PEER you want to be displayed or hidden peeeeeeeeeeeeeeeee9 fi iDisplay c Battery capacity shows the actual capacity reserve capacity and percentage of battery string d Data form shows the individual discharge data by t
16. nu 4 6 2 Press Chart to see the histogram for each cell in the string For more than 24 cells press Next Prev to see the other pages Page 17 30 SBS SBS 8400 USER MANUAL gt gt gt O i 4 6 3 Both the table and chart interfaces show 24 cells at a time If the tested battery string has more than 24 cells press the Next amp Prev to see the other cells 4 6 4 Press Exit to go back to the main menu 4 7 The Preset Function 4 7 1 The preset function allows 30 programmable locations to save discharge test setups You can select any of the preset tests and press Apply to use those discharge parameters The SBS 8400 supports manual setting in the discharge interface without using the preset features Press Preset on the main menu to enter the preset interface Preset parameter number TestTime the discharge time TestCurr discharge current if AhRate The rated capacity of the tested battery string Parameter 01 30 choose CCurrent Mode TestCapa the capacity need HourRate The hour rate of to be discharged discharge BattSum cell qty in battery SaveTime the time interval string of the data recording GrpLowV the lower limit TestMode EATER Baan Default voltage of battery string CCurrent constant current CKW constant power BattLowV the lower limit voltage of cells PowerSet discharge power if Recover all parameters using CKW mode aeaeaie
17. oftware in the process of discharging the data file still is being recorded in the background as long as the software is running Page 27 30 SBS SBS 8400 USER MANUAL i eee 5 4 Download Data File to a USB Disk 5 4 1 Download the data file from the main machine you can find the data file named Fxxxxxxxx FBO xxxxxx is the time amp date of data downloading 5 4 2 Double click the file to open the Battery information interface Or you can open the software first and choose Open file in the file menu PC Explorer Software can load the parameters which you set in main machine automatically You can fill in other non essential information or change Drive Tools Home Share View Manage the red parameters if you want O x F mone ae nea _Battery Information z Paste shortcut x folder e 4 gt ThisPC gt Removable Disk E Battery Model Company Test Unit Type SBS 8400 j C Name lene Battery Manufacturer Site Name Location Test Type esktop F2014 11 10 13 41 26 FBO gt Discharge ty Downloads lt Recent places Battery Type Battery ID Test Duration Lead Acid EA 03 00 00 Nominal Capacity AH Production Date Stop Reason 2000 11 10 2014 Discharge Time Up Battery Test Software Realtime Monitoring Opti Open File Hour Rate Current A Installation Date Note G 300 11 10 2014 StringLowVolt47 0V CellLowVolt 1 60 Number of Strings Company Tech Name Ce
18. old is reached in master SBS 8400 the parallel SBS 8400 also has the same settings so it will also terminate the discharge at the same time Page 25 30 5S SBS 8400 USER MANUAL nn TESTY FRI MEN 5 PC Software Instruction 5 1 Main Functions a Recording real time discharge data by connecting the SBS 8400 with a PC b Read display and save the downloaded USB data c Generate EXCEL test reports 5 2 Install Analysis Software To PC 5 2 1 Install the software SBS 8400 Manager from the CD ROM or USB disk 5 2 2 Follow the screen prompts to finish the installation 5 2 3 After the installation you can click on the desktop icon to open the software PC Explorer Install Program Home Share View Manage l re y Se BEXT Wej Copy patt j Paste __ Move Cop Delete Rename New a Paste shortcut to tc folder SBS 8400 Manager gt Thi 4 isk D gt T This PC Local Disk D Click Exit button to exit the installation wizard Favorites Name E Desktop SBS 8400 Manager exe gt Desktop Icon X Cancel Page 26 30 ZAS SBS 8400 USER MANUAL nn TESTY eres 5 3 Real Time Recording During Testing 5 3 1 Use the RS232 connector to connect the SBS 8400 with a PC RS232 to USB Converter 5 3 2 Choose Connect in the Real time monitoring menu to open the Real time Monitoring Link interface SBS 8400 Manager File Realtime Monito
19. onnect to cells NO 1 NO 4 from positive NO 2 module Connect to cells NO 5 NO 8 from positive NO 3 module Connect to cells NO 9 NO 12 from positive poy T MOJI A P ae of Paes MOJ PA DV MO PA e e ji e NO 1 Wireless module E i ae sas uoa iaa NO 1 Wireless module Cell Cell e Cell Cell 7 NO 2 Wireless module NO 5 NO 6 NO 7 NO 8 l l I Cell NO K Wireless module NO 4K 1 NO 4K 2 NO 4K 3 NO 4K 4 4 4 1 1 Reading the module number from the modules labels find the correct cells to connect the module to Do not connect the modules to 4 batteries which are not in series like No 1 5 8 9 misconnection will likely damage the module immediately 4 4 1 2 Use the alligator clips 1 red 1 black 4 yellow to connect modules to the batteries Please follow the correct wiring rule Yellow 1 to Yellow 4 from long to short A wiring diagram is printed on the label of the modules for your reference Page 11 30 Z4AS nh TESTY FRYE MEN SBS 8400 USER MANUAL 4 4 2 SBS 2612 wireless modules for 12V 6V connection Red to cell 4 gt Q Wireless module number and the battery to connect For example NO 1 module Connect to batteries NO 1 NO 4 from positive NO 2 module Connect to batteries NO 5 NO 8 from positive NO 3 module Connect to batteries NO 9 NO 12 from positive Cell Cell Cell Cell Cell NO 6 ala Cell e Cell C
20. r interface 4 8 2 In the parameter interface you will see all the same parameters as in the Preset you can re edit the discharge parameters here and press Apply to save them 4 8 3 Press Start on the discharge interface and turn on the FO breaker if the battery string is connected correctly to the unit by power cables you will see battery string voltage in GroupVolt 4 8 4 Press Start again to start the discharge LCD will show a Popup window to ask you to verify if all fans are working Then a popup window again will ask you to turn on the FT breaker The test will begin automatically as soon as FT is closed 4 8 5 Manual stop the discharge press Pause to pause the discharge and press Stop to end the discharge or press Start to continue the discharge Press Modify to locate the preset parameters Parameter needed to be changed to change value Cancel to quit After desired values are entered press Apply to save and the desired changes will be updated to Preset Back to the main menu Parameter 01 Cancel GroupVolt 050 1V BattLow 001 Current 000 OA TestTime 00 00 00 TotalPower 000 0KW CapaSum 0000AH When the discharging starts you can see the status in this screen it includes GroupVolt the voltage of battery group Current the discharge current an TotalPower the discharge power
21. racys 0 05 12V cells resolution 0 01V accuracys 0 05 2 7 Protection amp Warning Protection features of the SBS 8400 2 7 1 DCinput overvoltage polarity reversal at battery connection DC over current during discharge and system over temperature 2 7 2 Warning light and audible alert will activate and the LCD screen will show message prompt 2 8 Data Management amp Communication 2 8 1 Discharge data management a Data sampling is saved continuously and automatically so test records are not lost even due to a loss of power b Allows for manual review of data c Allows for reading amp downloading data via the communication port d Displays the remaining capacity of the internal memory e Smart delete selection delete all or delete the selected record from memory Page 6 30 SBS SBS 8400 USER MANUAL E ikl e A 2 8 2 Preset Test Parameters The Preset interface allows the user to program and store in the internal memory of the SBS 8400 up to 30 test preset parameters for quick selection and setup 2 8 3 Communication a Internal wireless signal receiver allows the SBS 8400 main unit to record the cell monitoring amp sampling data b Via the RS232 port in SBS 8400 main unit a PC can be connected to display real time discharge data c Via the USB port in SBS 8400 main unit test result data can be transferred to a PC by a USB disk d Via the Parallel control port SBS 8400 main unit can control
22. ring Option Window Help e Connect Battery Information input all information for the battery string the red fields must be entered Realtime Monitoring Setting Test Unit Type Battery Information SBS 8400 Battery Model Company Communication Port Choose the COM port number you Communication Port COMI Battery Manufacturer Site Name Location can find it in the Device Manager Battery Type i Battery ID Num ber of Stri ngs th e num ber of Nominal Capacity AH Current A Production Date Installation Date l 500 50 5 17 2009 z 5 17 2009 strings to be tested at the same time Peas Se nena a Seen Usually it is 1 Data file setting 10 100 iea CallVoltage V _ _ s of Batteries String Test DateTime 2 0 le 124 11 10 2014 Save Data after filling in fields press Save to create a FGDF file to save the real time data If you test more than 1 string at a time the option Duplicate can create multiple files for multiple string datas After saving the file press Connect to enable recording real time data 5 3 3 Start the discharge on the SBS 8400 the real time data will begin showing in the PC software interface Please input the red parameters correctly in the battery information screen as it can affect the result of capacity calculations 5 3 4 The real time data can be saved simultaneously even though you minimize the s
23. ring with power cables b Connect external current clamp to the SBS 8400 DC CURRENT MEASUREMENT port and put the clamp on the negative cable s from SBS S unit s to battery string c Connect parallel control wire from SBS 8400 PARALLEL INPUT port to SBS S EXTERNAL CONTROL port If there are 2 SBS S units please contact us to order the special control wire SBS 8400 4 12 1 2 Setting a Select the correct Clamp range in SBS 8400 Setup interface b Set all 4 stop thresholds and other details in SBS 8400 parameters interface and set the total discharge current to TestCurr you need for example 200A in total c Set all stop thresholds in SBS S unit s and set current to the max value which SBS S unit s is rated example set 100A in SBS 1110S d Save all setting in SBS S unit s and leave LCD on the discharge screen DISCHARGE STOPPED VOLT 123 5V AMP 000 0A CAPACITY 0000 AH TEST TIME 00 00 00 SBS S unit discharge screen 4 12 1 3 Discharge a Start discharge on the SBS 8400 and when the current increases to the max value the SBS 8400 can offer it will send out control signal to SBS S unit s SBS S unit s will start discharging up to the settings value for total current b External clamp will add all discharge currents from SBS S unit s to SBS 8400 And SBS 8400 will regulate the proper current to keep the total current set For example 200A in total if SBS S o
24. roduction Battery based backup systems have become an ever increasing source of providing emergency power to critical systems and components Maintaining these systems and knowing that they will be able to perform when called upon in an emergency has led to an increasing demand for testing methods to guarantee reliable operation In addition new requirements and recommendations FERC NERC IEEE etc are requiring more stringent attention to the reliability and performance of batteries used in these critical applications As we know there are many factors which determine the actual service life that a battery string will reliably perform before failures or reduction in capacity requires replacement While period maintenance and routine monitoring of measurements gives you some idea of a battery s condition it is only by actually testing the capacity of the battery string that you know what its capabilities are and how close it is to its end of useful service life With these ideas in mind SBS has developed the SBS 8400 as an advanced highly accurate and intellectual testing system for conducting load testing of battery strings With innovative features such as wireless data collection real time monitoring and integrated software the SBS 8400 is the tool of choice for consistent reliable and affordable battery capacity testing Advantages of the SBS 8400 a Wireless battery monitoring technology Available for 1 2V 2V 6V 12V cell
25. s 6 1 For safety and ease of use please read the complete manual before operation 6 2 During testing we suggest the operator stay in the vicinity of the testing unit 6 3 Please check the specifications of the SBS 8400 to ensure the tested battery string is in the voltage range If battery string voltage is out of the SBS 8400 s test range it could cause damage to the unit 6 4 If you need to record the performance of each cell in the battery strings wireless modules are required accessories Without them the PC analysis software can t collect the cell data to produce the voltage drop curves to analyze 6 5 If an over temperature over current or an equipment failure occurs during the discharge the warning alarm will activate automatically Please turn off the DC breaker amp AC input to avoid a further possible damage to the equipment 7 After Sale Service STORAGE BATTERY SYSTEMS LLC N56W16665 Ridgewood Dr Menomonee Falls WI 53051 Phone 800 554 2243 Fax 262 703 3073 Website www sbsbattery com Page 30 30
26. s voltage monitoring b Each wireless module can monitor 4 cells simultaneously Compared with traditional methods where each module can only monitor 1 cell the new module design requires only a quarter of the number of old fashioned modules Only 6 wireless modules for 48V battery strings c Parallel monitoring of multiple battery strings The SBS 8400 can simultaneously record the actual discharge currents and voltages of each battery strings under test Accessories extra current clamps are needed for multi string testing d Automated constant current control during on line tests During the discharge the current displayed in the LCD the discharge current of battery string The SBS 8400 is capable of monitoring the current created by the main machine the current of the actual load This allows for testing the battery system and automatic adjustment based on the system real and artificial load e Selectable number of low voltage limits This feature allows the test to continue instead of stopping as soon as the first cell reaches the low cell voltage setting and allows for testing to continue after a weak bad cell is jumped out of the string Page 3 30 A SBS 8400 USER MANUAL E ikl e A f g h k Simplified menu design The simplified menu allows for easy test set up and operation Light weight alloy heat sink elements New generation materials increase safety and thermal transfer of heat to air
27. se DataType AhRate 0500AH TestCurr 050 0A TestCapa O200AH TestTime 04HOOM BattLowV 01 80V GrpLowV 043 2V Battsum_ 024 Strings 001G USB press USB Plug USB into the USB port Highlight the file to download and The used percentage of internal memory if this value is low please delete some old data The information of the data file Delete Delete the selected file DelAll Delete all data files Back to the main menu Use RS232 cable to connect main machine RS232 port with a PC Select the file to download from the software interface on the PC Page 20 30 74 SBS 8400 USER MANUAL RATIER TESTY eres 4 10 System Setup 4 10 1 Press Setup in the main menu to enter the setup interface System date amp time Press Modify to locate the parameters need to be changed InputType for Setup to change value SBS 8400 this item is locked at Touch n ConfigModuleAddr assign spare Touch module to No you need Please follow S10 0 BattLowAct automatic Fran Baf 4 4 5 2 Activate No O spare modules operation when the 000 Ml 01 FM number of BattLowV 200A ModuleFreq change frequency of 1 g is over BattLow wireless receiver for working with different frequency wireless modules Stop or Pause Clamp range change the external current clamp range for different BattOrder wireless mod
28. to record the charging process data 4 11 2 Press Charge on the main menu to enter charge interface and press start to record the charging process data y tt Ww calibrated to change value Cancel to quit and Dischg calibrate discharge current 000 0V 000 0A 000 0A 000 0A Apply to save the changes Charge calibrate charge current 14 C 001 00 000V Clamp calibrate external current clamp TEMPE calibrate the temperature Back to setup interface BattVol calibrate the battery voltage GroupVolt the voltage of battery string GroupVolt 050 1V TestTime 00 00 00 When pressing Start to record the charge you can see the status in this screen It includes Current the charge current external clamp needed Current 000 0A CapaSum 0000AH CapaSum the capacity charged external clamp needed G Curr A Capa AH TestTime the time since the charge started 1 000 0A 0000 MaxBatt V the highest voltage battery in the group MinBatt V the lowest voltage battery in the group To browse all cells voltages Back to the main menu Table amp Chart screens are similar with the one in BatteryView Page 23 30 VAS SBS 8400 USER MANUAL nt TESTY eee 4 12 Multiple Units in Parallel 4 12 1 SBS 8400 SBS S unit s in parallel 4 12 1 1 Connections a Connect SBS 8400 amp SBS S unit s to battery st
29. ule should fail E gi No O Spare module label 12 00 00 4 4 5 2 To Activate a No O spare module To h When any assigned module fails for example No Stop Inc From Batt 3 module you can connect one of the spare E IF a f Los Module No __ Battery No 2014 01 01 200A Page 15 30 SBS SBS 8400 USER MANUAL nth TESTY FRYE MEN modules to 4 cells just like a normal module Disconnect all other modules Re address the spare module to No 3 to replace the failed one by entering the Config Module Addr of the Setup menu Set 003 and press config The spare module will become the new No 3 module 4 4 5 3 How to Erase and Reassign the Assigned Modules Numbered If you run out of spare modules and one of the assigned modules fails for example No 3 module fails you can erase No 15 and reassign to No 3 for this urgent requirement a Open the No 15 module box you will see a small button on the PCB Yellow frame in the picture b While holding this button down continuously connect it with 4 cells just like you would a normal module It will power on and then wait 10 seconds Release the button c Check BatteryView in LCD if Cells 57 60 normally on No 15 module have no data it means No 15 module has been reset to a No E O spare one d Follow the procedure in 4 4 5 2 To Activate a No O spare module to edit it to No 3
30. ules Cal change Date to 2099 12 XX clamp type 100A 200A 600A connecting reference from the Cal button will be activated for positive or negative main terminal entering the Calibration interface 4 10 2 BattLowAct allows control of what happens when the number of battery lows is reached Failing cells can be jumped out and the test continued Choose Pause the discharge can then be continued when you adjust settings and Start again the whole process will be recorded as a single data file 4 10 3 When cell No of your battery string starts from negative electrode please set BattOrder to From Batt SBS 8400 will reserve 4 cells sequence for each wireless module to keep your testing results correct Cell No start from positive gt gt From Cell No start from negative gt gt From Module Page 21 30 SBS SBS 8400 USER MANUAL nt TESTY FRYE MEN 4 10 4 ConfigModuleAddr please follow 4 4 5 2 Activate No O spare modules for assigning a spare module to act as the one you need 4 10 5 If two SBS 8400 units with 2 sets of wireless modules are testing different battery strings in same battery room the modules will have an interference problem and will not be visible on both units In this test application the units will need 2 sets of wireless modules with different frequency settings ModuleFreq setting can be used to change the frequency of the SBS 8400 wirel
31. wnloading and analysis through real time communications or USB memory device downloads The software interface includes battery cell voltages curves and bar charts group voltage curve current curve capacities histogram and a raw data matrix Powerful capacity calculating function the software calculates the capacity of each battery in the tested group The software shows the data in various forms such as bar charts curves and table formats Users can magnify or minimize any windows to view more details Automatically creates EXCEL data reports convenient to send or download the data SBS 8400 has multiple protective functions which include the audible alarms warning lights and clear interface prompts SBS 8400 is a compact lightweight simple to operate and highly accurate testing platform SBS 8400 is versatile in its ability to discharge test 12V 24V 48V 72V 96V 110V 120V 220V 240V battery strings etc across many applications Page 4 30 ZASE SBS 8400 USER MANUAL ne TESTY FRYE MEN 1 2 System Components The SBS 8400 battery capacity tester includes the main machine wireless modules for cells monitoring optional wireless signal receiver and PC analysis software The main unit consists of a color LCD screen data processing unit data monitoring unit auxiliary power unit power consumption unit and panel operation unit color LCD screen main machine data processing unit wireless modules for
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