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Battery capacity testing is carried out through a battery divider cabinet.

Principle of battery capacity detection:

The first step is to fully charge the battery to the rated voltage, usually 4.2V

The second step is to discharge the battery to the rated voltage and record the amount of discharged electricity, which is generally 3.0V

Step three, charge the battery to the normal level, usually set at 3.8V-4.0V

The capacity recorded in the second step is the capacity of the battery.

The capacity of the battery can only be measured using a professional battery comprehensive index tester. However, ordinary users cannot use a universal meter to measure the capacity of the battery, and a universal meter can only measure whether there is a damaged 2-volt unit in the group of batteries. The detection of capacity can only rely on usage, viewing, and estimation to basically determine the quality and remaining capacity of this battery. How to detect electric vehicle batteries? Take the 48V 500W electric vehicle as an example: to determine if there is an internal short circuit (bad battery) in the battery: for a car that has been ridden for a while or has been left idle for several hours after being charged, measure the voltage at the charging plug, and if it is 48V or slightly higher, it is a normal battery (regardless of old or new). If it can only reach 46 volts or less, it indicates that one battery has a short circuit (there are four sets of batteries in a 48 volt car, each consisting of six 2-volt batteries connected in series to form 12 volts), indicating that the 10 volt set is a faulty battery. Note: When one battery has a short circuit (only this group of 10 volts out of four batteries), and the total voltage can reach 46 volts, the charger can still display full charge and green light, but the charging time is 0.5-1 hour longer (there is a slight risk of overcharging); When there is a short circuit between two or more batteries, using a charger specifically designed for charging 48V batteries to charge batteries below 46V will never fully charge the green light (all batteries are in the risk of overcharging damage). In this case, simply replace the battery pack that is less than 12 volts among the four groups. Judging whether the battery is old or new, and judging whether it is scrapped: a 48V electric vehicle with a 500W motor: ① If, just after being fully charged, suddenly accelerating while riding, the power meter needle only drops less than half a grid (one small scale), it is a new battery. ② After being fully charged, if you suddenly accelerate your ride and the battery indicator drops one grid, it becomes a semi new or old battery After being fully charged, if you suddenly accelerate your ride and the battery gauge needle drops 2-3 grids, it is an old battery that is about to be scrapped (it will self discharge and run out even if fully charged for half a month without riding) After being fully charged, if you suddenly accelerate and ride more than four grids, the battery will be scrapped. (If fully charged and not ridden for a week, the battery will self discharge and run out.). If it is a 64 volt 500 watt car that has just been fully charged (at the same power, the higher the voltage used, the corresponding decrease in motor current), then: ① If the car suddenly accelerates while riding and the battery indicator is at its maximum and basically does not move, it is a new battery. ② If you suddenly accelerate your ride and the battery gauge needle falls half a grid, it becomes a semi new and old battery If you suddenly accelerate your ride and the battery gauge needle drops 1-2 grids, it is an old battery that needs to be scrapped quickly If you suddenly accelerate your ride and the battery gauge needle drops more than 3 grids, it is considered a discarded battery. Note: The above are the empirical estimation parameters for the best battery capacity when the temperature is 25 degrees Celsius. If it is in winter below 15 degrees Celsius, the electricity meter should be observed to decrease by an additional 0.5-2 grid, because the charging and discharging efficiency of the battery will decrease by about one-third (i.e., the capacity will decrease and the internal resistance will increase) when the temperature is below 15 degrees Celsius. The above estimation method is based on the fact that the newer the battery, the smaller the internal resistance. Under the test of sudden acceleration at maximum current, the old and scrapped batteries will appear! I hope it can be helpful to my friends. If you have any questions, please follow up.

The battery capacity tester is specifically designed for conducting verification discharge experiments, capacity testing, daily maintenance of battery packs, engineering acceptance, and testing the carrying capacity of other DC power sources on battery packs.

Using the latest wireless communication technology, the discharge process of the battery can be monitored in real-time through PC monitoring software, monitoring the discharge process of each battery. The power consumption part adopts a new PTC ceramic resistor as the discharge load, completely avoiding the phenomenon of red heat, safe, reliable, and pollution-free. The whole machine is controlled by a microprocessor, with LCD display and Chinese menu. The appearance design is novel, small in size, light in weight, and easy to move. After setting various discharge parameters, the entire constant current discharge process is automatically completed. Fully realize intelligence. Make the entire discharge process safer.

The portable and intelligent professional design of the intelligent discharge monitoring instrument makes the discharge testing work simple and easy, greatly reducing the labor intensity of professional maintenance personnel and improving the scientificity and intelligence of discharge testing.

On the basis of the original product, a new generation of single cell detection whole group discharge instrument with wireless single cell detection function is launched by combining battery testing technology, wireless communication technology, computer information processing and other technologies. By adopting a wireless transmission unit voltage collection system, data can be transmitted wirelessly over short distances. The data collection speed is fast, the accuracy is high, the anti-interference ability is strong, and the operation is simple. It can record the voltage changes during the battery discharge process at each time period, effectively avoiding safety hazards such as errors caused by wiring and damage to connecting cables. The wireless collection unit voltage generates "bridge voltage" between the connecting wires of the battery, ensuring that there may be large connection resistance due to loose individual connectors during the discharge process, thereby monitoring individual voltage abnormalities, timely eliminating hidden dangers, and preventing major accidents such as fires caused by overheating at the connection points. This enhances the stability and reliability of the system and expands the range of product use.

There are two main methods for monitoring the voltage of traditional single cell batteries: manual measurement and wired automatic measurement. Due to the inability to achieve continuous and synchronous measurement over time, manual measurement results in high human error and low accuracy, making it difficult to make accurate and objective judgments on the performance of batteries, and the workload is large. Although wired automatic measurement improves the speed and accuracy of data collection and reduces workload compared to manual measurement, it has more connections and complex operations. Taking the detection of a group of 24 individual batteries as an example, 25 individual test cables need to be led out from the host to connect to the battery pack, with lengths ranging from one meter to more than ten meters. This not only increases the purchasing cost for enterprises, but also makes it easy to make connection errors due to the large and long connection cables, and cannot avoid safety hazards such as cable damage.

The use of a wireless transmission single cell voltage acquisition system for single cell detection of the entire set of discharge instruments effectively overcomes the shortcomings of traditional single cell battery voltage monitoring methods. The wireless transmission unit voltage acquisition system adopts Nordic's latest nRF9E5 chip with built-in reference function, greatly improving voltage acquisition accuracy and data confidentiality. At the same time, it is equipped with a high-speed CPU to process the collected data. Each wireless transmission unit voltage acquisition system can simultaneously collect multiple unit voltages,. Wireless function settings can be achieved through the host, with high transmission power, reception sensitivity, and anti-interference ability. Based on FSK modulation, efficient forward error correction channel coding technology is adopted to ensure the accuracy of measurement results. The ISN band can be used without application and can adapt to various data transmission formats such as 232, 485, LIN, etc., providing convenience for data processing.

Adopting a new generation of single cell detection and whole set discharge instrument to monitor individual batteries, without the need to connect the individual battery to the host, it can be directly tested, which is convenient to use and reduces the purchase cost for enterprises.

This manual is used to guide users in operating the HDGC3982 intelligent discharge monitor.

1. The operator must have the qualifications of an electrician or above.

2. Operators should pay extra attention to the safety of personnel and equipment during use.

3. The RTKR-II intelligent discharge monitoring device belongs to precision testing equipment. It should be handled with care and not thrown or dropped randomly during use. Mild results may cause deformation of the shell, while severe cases may cause internal component failures, affecting normal use.

4. Avoid splashing liquid onto the surface of the intelligent discharge monitor to prevent permanent injury caused by entering the system, as flammable gases may cause explosions.

For your safety, please read all the contents of this manual before operating the intelligent battery discharge device. Measurement personnel should be familiar with the characteristics of the tested system. It is very important to take the correct testing steps to avoid injury to oneself and others in the work area, as well as damage to the testing equipment.

We assume that the operator has a comprehensive understanding of the battery, charging system, and device startup before using this tester. Before using this tester, please refer to and follow the relevant safety precautions and the testing steps provided by the manufacturer of the tested equipment.

Security information is used to prevent personnel injury and equipment damage.

Read, understand, and comply with the safety information and instructions in this manual, which includes:

danger Indicates a very urgent and dangerous situation that, if not avoided, may result in serious casualties.

Warning! Indicates a potential hazardous situation that, if not avoided, may result in serious casualties.

Attention! Indicates a potential hazardous situation that, if not avoided, may result in general personal injury.

Important! Indicates a potential hazardous situation that, if not avoided, may result in damage to the testing equipment.

Important safety guidelines

Warning!

Explosion hazard! The gas generated by batteries is highly explosive.

Read, understand, and follow all instructions related to the tester, battery, and any other equipment near the battery.

Smoking, lighting matches, and placing metal tools near batteries or creating sparks near batteries are prohibited.

Before using the tester, the wiring terminals should be cleaned thoroughly. Pay attention to protecting your eyes, nose, and mouth during cleaning. Use soda and water to neutralize acidity and reduce the corrosiveness of air.

Do not place the tester in rain, snow, or damp environments.

Do not allow battery gas or sulfuric acid to come into contact with the housing of the tester.

Never charge, test, or load frozen batteries. Before performing the above operations, thaw the battery and warm it to room temperature. Charging or attempting to test frozen batteries can cause the battery to explode and result in personal injury.

Before conducting the test, it should be confirmed that all test joints are connected according to the instructions.

Ensure that the two battery clips are securely connected to the battery.

Battery explosions can cause casualties.

Warning!

Prevent burns

The current generated by a battery short circuit is sufficient to melt various ornaments and weld them onto metal. When working near the battery, remove various decorations.

A short circuit will cause injury to personnel.

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