BFGS Series Battery Formation, Grade and Testing System Users’ Manual

BFGS series
(GFGS-8128/8256/8512/9256)

BATTERY FORMATION、 GRADE AND TESTING SYSTME

USERS’ MANUAL
VERSION 6.04.03.16

Addr: 3F, Antong Building, 207 Meihua Rd., Xiameilin, Shenzhen, China ZIP: 518049
Tel: 0755-83128938 Fax: (+86-755) 83109966
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

Contents

Preface
1. Products introduction
Summarization
Characteristic
Technical criteria
Diagram of network configuration
2. Formation and Grading configuration
Diagram of Battery Cupboard
Using Main Menu
Menu List
Channel Definition
3. middle computer operation
Boot-strap
Battery installation
Step Setting Parameter
Start-up
Channel State Display
System Operation
Grading
Channel Operation
Shortcut key Explain
4. Upper computer software
Software basic operation
Operating current test
Dealing data
Capacity formation
Battery match
Look over historic data
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

Preface

 Thanks for using the series NEWARE BTS (Battery Testing System).

 Please read the manual carefully before using the system to give full scope to the
functions of system.

 Our company devotes to providing range of battery testing systems, battery formation &
grading systems, internal resistance testers as well as battery cells. Our products have
been passed through strict internal test procedures and are certified by the national
quality inspection authority. With five years’ continuous renovation, our products are
rewarded as mature technology, stable quality and leading performance and widely
accepted by both domestic & overseas customers.

 Our company registered trademark is “NEWARE”. Company's management strategy is

“technological innovation, sincere service”. The company attaches great importance on
constantly pursues the most superior performance price compared and consummation
post-sale service to satisfy our customers various requests.

 Want to see more details of our company and software downloading, please visit
http://www.neware.com.cn

 Our company customer service is: 800-830-8866, all expense is paid by our company.
After receiving the requests, if you need on-site maintenance, our servicemen will get at in
the first time to guarantee productions are carried out normally.

 We provide free maintenance during one year after the sales, and only charge for the cost
after the guarantee period. We will constantly follow the status of our products by
contacting our customers. Please also note that we will timely provide the latest upgraded
software of our products to our customers all the time.

 Addr.: 3F, Antong Building, 207 Meihua Rd., Xiameilin, Shenzhen, China
 Zip: 518049
 Tel: 0755-83128085
 Fax:0755-83109966
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

Summarization

Neware BFGS-8512 batteries formation, grading and testing system is designed for
Lithium-ion; nickel-hydrogen batteries formation and grading test, also can be used to
batteries life cycle test.(BFGS-9526 batteries formation and grading test system is designed
for Lithium polymer batteries formation and grading test system.

Advanced computer data centralize collection and control software (network connectivity and
SQL database), with itself keyboard and Large LCD with Chinese characters (full Chinese
man-machine conversation interface),digital current and voltage automatic calibration. This
system is the ideal choose for large-scale battery factories.

The system is composed of upper, Middle and Lower computer .Above machine is composed
of a computer and controlled software. Middle machine compose of Single Chip
Microcomputer and screen. Each middle machine controls 8 or 23 low machine . Low machine
is deviced by model. Each Low machine composes of independently 16 battery channel.
One middle machine and 8 or 23 Low machine compose one battery case. Each battery case
can sork not only in middle machine control but also in above machine.

Characters:

1. Adopting network connectivity and SQL database, concentrate control several machine (join
255 maximum; 65280 points.)
1.Absolute MPU for each channel, single-point control with quick-rate and high-accuracy
2.Independent constant-current source and constant-voltage source
3.Undisturbed switch between constant-current and constant-voltage
4.Automatically correct the digitized errors with high speed and accuracy
5.Large LCD with Chinese characters, easy operation

6.Combined with computer to integration control, data integrated analysis, statistic, report,
print, etc.

7．Charge flat-roof grade and curve grade;

8.Module construction, high reliability, each module provides 16 independent channels, this
function is convenient for the system’s maintenance
9.Industrial programming design, all the operation carry out automatically according to the
designed working steps
10.High accuracy, fit with small current grade(〈10mA〉

Product compares:

Neware BFGS Series Other products

1 Testing accuracy is 0.4% Testing accuracy 0.1%
2 Sampling voltage and current Just sampling a certain channel which lead other
real-time channels to run away temporarily
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual
3 LCD with Chinese display with big LED display, operation is complex
screen directly and easy-to-operate
4 maintain and debug with software, Maintain and debug with hardware, the accuracy
easy-to-operate, steady accuracy is easy to float
5 Industrialized program design, all Need change running status artificially
the operation carry out automatically
6 With import air-switch, cut switch Without
when over load automatically

Technical criteria

Type BFGS-8512 BFGS-9256

Input power 220 V ±10% / 50 Hz The same as left
Current output ranges ±2000 mA The same as left
Voltage measure ranges 0.1-5V The same as left
Power 8300 W 4100W
Current measure accuracy ± （ 0.2% reading + 0.2% The same as left
ranges）
Voltage measure accuracy ± （ 0.2% reading + 0.2% The same as left
ranges）
Timing ranges 0~9999 minute/work step The same as left
Constant voltage cut-off 5mA minimum The same as left
current
Polling time Real time The same as left
Separation conditions Time/capacity/platform The same as left
Clamp adjustable ranges 80mm maximum, space The space between two
between clamp is 34mm electrode is 30mm
Cycle ranges 250 The same as left
Numbers of each channel 512 256
Port RS232/network port The same as left
Volume 1450 (W) x 380 (D) x 1700 (H) 1450 (W) x 340 (D) x 1700 (H)
Weight 350Kg 200kg

2. Formation and grading equipment

Diagram of Battery Cupboard
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

① Controlled Panel
In it include Display Screen, Keyboard, Power on/off, Indication lamp and other fittings, all
operations are accomplished by it, and can be real-time monitored and manage by the
computer. Each computer can control more than 255 battery cupboard.

② LCD with Chinese display with big screen

③ Passes up and down LED

Display the battery cupboard adopt the data and real-time control through it's circulate.

③ Power On/Off

⑤ Power LED

⑥ Pellicle keyboard
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

0-9，. Number Key ←┘ Ensure the input content ↑ ↓ ← → Up、Down、Left、Right

move current position Start Start the process for working Grade Go to Grading
statement C Quit the process and clear the mistake F Press this button before input
digital.

⑦ Battery channel
Used to install that is formation & grade deal with the second battery.

⑧ Channel state LED

Light on/off has different meaning in different working state, the details as followed:

 Using main menu

The main menu is a system display in the screen, through this get into the second or three
stage menu. For the ↑↓ is switched with each main menu, the ← is switched in the second
or three grade menu and the C is switched for quit.

Display channel state

Function select Setting step parameter
Display channel state System operation
Select ↑ ↓ Ensure ←┘Quite C
Channel code operation
Channel operation

Press the “↑” “↓” for switching menu

 List Menu
With full Chinese display, no matter when using main, secondary or third menu, it is

convenience for searching and easy to use. The menu is consistent with switch manner

and operation method, easy to use. Very menu catalog as follows:

 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

Setting step parameter②

Display Channel State (Viewing) ①
64 Platform set
Platform 1 Display channel working parameter
Platform 2
Display channel grading parameter
Platform 3
0 Initialization
Start Step System Operation

Voltage Upper Limit 3

Forcedly Jump○
Voltage Lower Limit Voltage detect ④
1 Constant-charging Stop (formation)⑤
Constant current
Continue (formation)⑥
Cut-off time
Cut-off voltage
2 Ni-MH Charging
Constant current Channel Number Operate

Cut-off Minute Channel Number Display⑦

-△v Channel Number Register⑧
3 Li-ion charging
Channel Number Clear⑨
Constant Current
Address Distribute
Constant Voltage
Cut-off Minute
Cut-off Voltage
4 Constant Current Charge Channel repair Operation
Constant Current Channel Zero
Cut-off Minute
Channel full range
Cut-off Voltage
Repair detction
5 Rest
Repair Parameter
Cut-off Minute
6 Circulation
Circle Step Startup
Circle Times Formation
7 Ending
* ② The number in circle is represent the shortcut key ,see details about Shortcut Key
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

Explain in the first chapter; “1 constant current charge” the number without circle is
represent work step number, see details in work step set chapter.

 Channel Number Definition

The battery cupboard include 8 rows channel, from up to down is the first row  the eighth

row, each row has 16/32/48 channel, each channel number include three data. The first

one is row number; the others show the place that in the channel. For example: when

some channel number is 325 so it means this channel is in the third row, from left to right

the twenty-forth channel.

3. Operation

 Startup
Turn the battery cupboard power on/off, the power pilot lamp light, the screen display

picture as follow:

XX Function Select V5.1

Cupboard No Channel state display

Version No Select ↑ ↓ Perform ←┘ Quit C

 Battery Installation

Before install the battery, ensure if the place of clamp suit the battery style. If not ,

through control handspike to adjust the place of clamp ,then screw the control

handspike and put the battery as each channel in order.

 Setting Step Parameter (shortcut key 2)

The system imply flexible step configuration for suiting different battery. The system

can set more than 63 steps, in it ,The”0”means “initialization”, the last one “64”means

“platform setup”.

0 work step initialization 64 work step platform setup

Press the key“↓” ”↑” to step parameter setup picture:

 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

Function select 0 step→ initialization

Setting step parameter Press“←┘”
►
Select↑ ↓Perform←┘Quit C Set data F Quit C

Though press the key“↑” ” ↓”to select step serial number, when display “►”,the setting

working content as follows:

1 Constant current charge

2 Ni-MH charge

3 Li-ion charge

4 Constant current discharge

5 Rest

6 Circulation

7 Ending

Notice: After press the number key to select step working content, ensure by “←┘”.

After selecting the step working content, press “→” ”←” to go to the current step .Each

step parameter as follows:

0 Initialization：

The parameter as follow:

0 Step → Initialization Start step: xx

► Voltage upper: xxxv

Voltage lower: xxxv

Set data F Quit C
►

“→”“←”：Switch between each menu

In above picture,” upper limit voltage、lower limit voltage” is system protection voltage, to
insure the battery voltage not exceed the set ranges. For the Li-ion battery, generally, set
upper limit voltage as set 4.3V and the lower limit voltage as 2.6V.
“Start Step” is using appointed the startup of the battery cupboard. The user can set
numerous working processes within 63 steps. From“ Start Step” to set which step to carry
out.
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual
6○4 Platform Setting

64 Setting → platform parameter Platform 1 x.xxxV

► Platform 2 x.xxxV
Platform 3 x.xxxV
Set data F Quit C ►

“→”“←”：Switch each menu

As “step setting” ”0 step →Initialization”, press”↑”get into “platform setting”. The user can
set three group of follow big to small platform parameter.
① Constant current charge
The parameter as follow:

Xx step → constant current charge Constant current x.xxx mA

► Ending voltage x.xxx V
Ending minute x.xxx M
Set data F Quit C ►

“→”“←”：Switch each menu

② Ni-MH Charge
The parameter as follow:

Xx step → Ni-MH charge ─△V：x.xxx mV

► Constant current: x.xxx mA
Set data F Quit C Ending minute x.xxx M
►

：Switch each menu

“→”“←”
③ Li-ion Charge:
The parameter as follow:
Constant current：x.xxx mA
Constant voltage: x.xxx V
Xx step → Li-ion charge
Ending current: x.xxx mA
►
Ending minute: xxxx min
Set data F Quit C
►
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

“→”“←”：Switch the menu

In “Li-ion charge”, set the constant voltage general as 4.20v, the cut-off current as

20-50mV, the cut-off time is refer to the charge/discharge times-rate, delay the minutes

adequate. As battery for 1CmA to test, the charge minute can set 90~120 min.

④ Constant discharge
The parameter as follow:

xx step → constant discharge Constant current：x.xxx mA

► Constant voltage: x.xxx V
Set data F Quit C Ending minute: xxxx min
►

“→”“←”：Switch the menu

In “constant discharge”, such as the channel end the discharge as some reason
suddenly, the restart the channel can press the “start ”key at “channel state
display”.

⑤ Rest

The parameter as follow: xx step → rest

Cut-off minute: xxxx min
Set data F Quit C

⑥ Circulation
Adopt this manner can circulate over again between you setting, more than 250 times

for circulate.

The parameter as follow:

xx step → circulate circulate step：xx

► circulate times: xxx
Set data F Quit C ►

“→”“←”：Switch each menu

 Startup
Press “C” to quit the default mune after set each parameter, press ”startup” and light
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

wink over on the control panel, displayed:

System perform operate

Success
Quit C

And the channel pilot lamp off, all the step order as follows.

 Channel state display(shortcut key 1 or 3)

Press “←”as system default and displayed:

Channel number xxx No.→XXXX Working state

Circulate step serial number Step xx minute xxxx: xx Circulate
minutes Cycle times xx
Display the cycle times U=x.xxxV I=xxxx mA Channel current
Channel voltage

Enter “Channel state display”, the channel No. display”000”, all the parameter is total

parameter. Time is Middle’s time, cycle times is current circulate state; As the Li-ion

charging, the voltage set “constant voltage”, the current set “constant current”. As

discharging, the voltage set “ending voltage”, the current set “constant current”.

Though press“→”“←”at “channel state”，the channel add or reduce 1, or input the channel

code by the keyboard to display channel’s parameter.

Press the “↓” ” ↑” to select other working parameter.

xx No. → XXXX
xxx No. →capacity parameter
step xx minute xxxx :xx
3.800V xx min xxx mAh
cycle times xx
3.600V xx min xxx mAh
3.400V xx min xxx mAh
2.750V xx min xxx mAh
If=xxx mA

Formation time is the last constant current charge time. If is the constant current discharge

value, Uk is starting discharge voltage. Uz is the discharge ending 3 minutes voltage

value.
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

 System operation
At the function select, press “↓” ” ↑”to “system operation”:

Function select
System operation

Select↓↑Perform←┘QuitC

① Voltage testing(shortcut key4)

At system operate, press “←”, display:

Voltage testing
System operation
x.xxxV x.xxxV
Voltage testing

Select↓↑Perform←┘QuitC
Select ↓ ↑ Perform ← ┘ Quit

Enactment the testing voltage value, press “←” ensure, displayed:

Voltage testing
System perform operation

Set data F Quit C

If the channel measure voltage between testing voltage ,the channel pilot lamp light.

② Stop (formation) (shortcut key5)

At stop, press “→”“←”at “system operation” to stop (formation) , point “← ”to ensure

System operation System operation

Ending formation Continue formation

Select↓↑Perform←┘QuitC Select↓↑Perform←┘QuitC

③Continue (formation)( shortcut key5)

Press “→”“←”to “Continue (formation)”at “system operation”, point “← ”to continue the

operation as “stop(formation)”or unfinished (formation) operate.

 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

 Formation
As all the channel pilot lamp light or “channel state display” is waiting for operate, explain

(formation) end operation, formation and assort battery.

The system formation the battery according constant current discharge.. Formation

timing-area follow >=Lower time value and <Upper area value to plot. The operation:

As system default, “formation”, displayed:

Formation Formation
xxx min - xxx min System perform pcs xxxpcs

Set data F Perform←┘Quit C Set data F Perform←┘Quit C

After enactment formation time interval, press” ←┘” to ensure, to apart all the battery at

constant current discharge time.

 Channel code operate

At function select press “↓””↑” to “channel code operate”:

① Channel code displayed(shortcut key7)

Channel code display

Channel code operate
101√102√103√104√
Channel code display
105√106√107√108√
109√110√111√112√
Select↓↑ Perform←┘Quit C
113√114√115√116√

The “√” render channel code register, the ”×”render channel code unregister, unregisted

channel can’t process (grade) and formation operation .

②Channel code register(shortcut key8)

At “channel code operation” submenu press “→”or“←”to “channel code register”:

Channel code operate 901 code channel clear

Channel code register system perform operate

Select↓↑ Perform←┘Quit C Set data F Perform ←┘Quit C

Input the unregistered channel, press “←┘” and register channel. At the “channel code is
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

901 ”state press “←┘”directly, to register whole cupboard automatically, success displayed

on the screen, that is register successful. Finish it and press “C” to quit.

③Channel number clear (shortcut key9)

At “channel code operation” submenu press

Channel code operate 901 code channel clear

Channel code clear system perform operate

Select↓↑ Perform←┘Quit C Set data F Perform←┘Quit C

Input dealing with channel code, press” Press“←┘” and clear the channel. Also can press”

Press“←┘” directly at channel code “901”.

④Address Distribution

put the short clump into the “J1” at the Middle circuit board signed, electrify again and

switch the menu to “channel code register”, input the channel and press “←┘”.Touch the

clamp of two poles ,the channel distribute address again.

Notice: Before distribute address, all the channel no battery.

 Channel adjust operation(shortcut key 0)

Use for adjust the error channel, generally use for needed. The detail is adjusting

operation explain.

 Cupboard number setting

Insert the short circuit into middle computer where has “JI” typeface. Then cut back

main menu, press “F” key, input the registered cupboard number, press “←┘” key, then

this cupboard number is reset.

Notice: Cupboard number can’t repeat.

 Shortcut key explain:

Press ”0” enter into “adjust testing”

Press “1” enter into “channel state”

Press “2” enter into “work step setting”

Press “3” enter into “forcibly jump”

Press”4” enter into “voltage testing” , press again to perform “voltage testing”

operation

Press”5” enter into “stop (formation)”,press again to perform” stop (formation)”

operation
 BFGS Series Battery Formation, Grade and Testing System Users’ Manual

Press”6” enter into “continue (formation)”, press again to perform “continue

(formation)” operation

Press”7” enter into “channel number display”, press again to perform “channel

number display” operation

Press”8” enter into “channel code register”, press again to perform “channel number

register” operation

Press”9” enter into “channel number clear”, press again to perform “channel number

clear” operation

Formation & Grade Monitored System Operate Software Explain

 Basic function:

1. Display function: real-time display battery cupboard charge/discharge current,

voltage, minute, capacity, battery working state and charge/discharge real-time

curve and data, etc.

2. Data stored function: Each battery testing data can store hard soft, easy to look

over, keep in the archives, statistic, table, print, etc.

3. Print function: Print every data needed momentarily.

 Software ,hardware condition:

Operation system

Microsoft Windows 98

Hardware

P5/200 or higher

64MB or higher internal memory

1.2G or higher hard disk space

 Installation

Get into Windows operation system; double click the “setup” at driver file.

 Basic operation:

Main interface introduction:

1. Toolbar explain

 Control button explain

 Protection parameter setting and Alarm channel display:

 Look over button---main working area