1. Introduction
The SUNKKO BAL-5616/8616 is an advanced lithium battery pack voltage analysis balancer and active equalizer designed for capacity repair. It supports 2S to 16S battery configurations and is compatible with ternary lithium and lithium iron phosphate battery types. This device utilizes an energy transfer balance mode to actively equalize cell voltages, reduce differential pressure, and restore battery capacity.
2. Features
- Active Equalization: Employs energy transfer balance mode for efficient cell balancing.
- Wide Compatibility: Supports 2S to 16S battery packs.
- Battery Types: Suitable for Ternary Lithium and Lithium Iron Phosphate (LiFePO4) batteries.
- High Current Balance: Available in 5A (BAL-5616) and 8A (BAL-8616) equilibrium current options.
- Real-time Monitoring: Provides real-time detection of equalization effects and voltage changes.
- Multiple Display Modes: Offers various voltage analysis display modes for easy monitoring.
- Adjustable Equalization Duration: Selectable durations of 1 hour, 3 hours, or 4 hours.
- High Precision: 0.1% measurement accuracy.
- Safety Features: Allows setting of alarm parameters for maximum voltage, minimum voltage, and pressure difference.
- Intelligent Cooling: Equipped with an intelligent cooling fan for sustained operation.
3. Package Contents
Please check the box for the following items:
- SUNKKO BAL-5616/8616 Active Equalizer Unit x 1
- Power cord x 1
- High-quality silicone wire x 1
- Cross screwdriver x 1
- 16S 3.81 socket x 1
- Line sequence detection plate-24S x 1
- Warranty & Instruction Manual x 1
4. Setup
4.1 Functional Controlled Panel Overview
The front panel features control buttons and an LCD screen for operation and monitoring. The rear panel includes the main power switch, intelligent cooling fan, power supply input, safety tube, and the 01-24S DIP switch.
- Turn ON/OFF key: Powers the device on or off.
- Voltage analysis display selection key (S): Cycles through voltage analysis display modes.
- Setting digit increase key (Up Arrow): Increases the value of a setting digit.
- Voltage display selection key (M): Selects different voltage display options.
- Setting digit decrease key (Down Arrow): Decreases the value of a setting digit.
- Power light: Indicates power status.
- 1h button: Initiates 1 hour of continuous equalization.
- 3h button: Initiates 3 hours of continuous equalization.
- AUTO OFF switch: Toggles automatic shutdown.
- LCD high-definition screen: Displays battery parameters and equalization status.
- Battery cell input port: Connects to the battery pack's balance leads.
- Main power switch: Main power control for the unit.
- Intelligent cooling fan: Activates to cool the unit during operation.
- Power supply: AC110V~220V input.
- Safety tube: Overcurrent protection.
- 01-24S DIP switch: Configures the number of series cells in the battery pack.
4.2 Wiring Diagrams
Ensure correct wiring from the total negative electrode (B0) in sequence. Incorrect wiring can lead to abnormal display or damage to the balancer.
4.3 DIP Switch Configuration
Before use, ensure all terminals are correctly wired. Then, set the DIP switch on the back of the balance controller to match the exact number of series cells (strings) in your battery pack. Failure to set the DIP switch correctly may result in abnormal screen display, garbled information, or permanent damage to the balance controller due to reverse connection of the line sequence.
5. Operating Instructions
5.1 Energy Transfer Balance Mode
The equalizer operates on an active energy transfer principle. When equalization begins, higher voltage cells transfer energy to lower voltage cells, aiming to achieve a balanced voltage across the entire battery pack.
The effectiveness of the equilibrium current is influenced by:
- The internal resistance of the battery pack: Smaller internal resistance leads to a greater equilibrium current.
- The resistance of connecting wires and connectors: Smaller resistance leads to a greater equilibrium current.
- The voltage difference of the battery: A greater voltage difference results in a greater equilibrium current.
5.2 Equilibrium Conditions (5A Current Test)
For optimal 5A current balancing, the following conditions should be met:
- Voltage difference between batteries: ≥ 1V
- Connecting flat cable battery resistance: < 8mΩ (single wire), >0.5mm²
- Internal resistance of battery: ≤ 15mΩ
- Connector resistance: < 4mΩ
5.3 Display Modes
The device offers four display modes for comprehensive voltage analysis:
- Entire string display mode: Shows the total voltage and overall status of the battery pack.
- Overall Analysis Mode: Provides a detailed overview of all cell voltages.
- Separate page mode: Displays individual cell voltages in a paginated format.
- Graphics mode: Offers a graphical representation of cell voltages for quick visual assessment.
5.4 Equalization Duration
You can select from three preset equalization durations:
- 1 hour: Press the '1h' button. The button will flash red.
- 3 hours: Press the '3h' button. The button will flash red.
- 4 hours: Press both '1h' and '3h' buttons simultaneously. Both buttons will flash red.
5.5 Setting Safety Parameters
The device allows you to set alarm parameters for maximum voltage, minimum voltage, and pressure difference to ensure safe operation.
5.6 Explanation of Equalizing Current and Differential Pressure
The equalizing current indicated on the module is the maximum current it can output or absorb. The actual current is influenced by the battery pack's internal resistance, connecting cable resistance, connector contact resistance, and the voltage difference between cells.
For continuous equalization, especially when the voltage difference is between 30mV-80mV, the battery voltage difference can be effectively controlled. The minimum voltage difference after equalization for a 16-series design is typically 15-20mV.
6. Maintenance
- Keep the device clean and free from dust.
- Store in a dry environment away from direct sunlight and extreme temperatures.
- Ensure proper ventilation; do not block the intelligent cooling fan.
- Regularly check all connections for wear or damage.
- Do not attempt to open the casing or repair the device yourself. Refer to qualified service personnel.
7. Troubleshooting
If you encounter issues, please check the following:
- Abnormal screen display or garbled information: Verify that the DIP switch setting matches the actual number of series cells in your battery pack. Ensure all wiring is correct and not reversed.
- No equalization activity: Check if the battery pack voltage difference meets the equilibrium conditions (e.g., ≥ 1V for 5A current). Ensure the device is powered on and the equalization duration is set.
- Device overheating: Ensure the intelligent cooling fan is not obstructed and the device is in a well-ventilated area.
- Inaccurate voltage readings: Confirm that all balance leads are securely connected and the wiring is correct. The device has a 0.1% measurement accuracy, so significant deviations may indicate a connection issue.
8. Specifications
| Attribute | Value |
|---|---|
| Brand Name | Sunkko |
| Model Number | BAL-5616/8616 |
| Place of Origin | China |
| Power Supply | AC110V~220V |
| Applicable Series | 2S~16S |
| Battery Type Compatibility | Ternary Lithium, Lithium Iron Phosphate (LiFePO4) |
| Equalizing Current (BAL-5616) | 5A |
| Equalizing Current (BAL-8616) | 8A |
| Equalizing Duration Options | 1 hour, 3 hours, 4 hours |
| Equilibrium Principle | Paralleling Energy Transfer |
| Measurement Accuracy | 0.1% |
| Minimum Equalization Voltage Difference | 0.01-0.02V (after equalization) |
9. User Tips
- Always double-check your wiring against the provided diagrams before powering on the device to prevent damage.
- Ensure the DIP switch setting accurately reflects the number of cells in your battery pack.
- For best equalization results, ensure your connecting wires and connectors have low resistance.
- Monitor the display during equalization to observe the voltage changes and ensure proper operation.
- If balancing a battery pack with a large initial voltage difference, consider using a longer equalization duration.
10. Warranty and Support
Please refer to the included Warranty & Instruction Manual for specific warranty terms and conditions. For technical support or service inquiries, please contact your retailer or the manufacturer directly.
