Test equipment for HV batteries
Charge and discharge high-voltage battery modules, balance cell voltages, and check for leaks
HV test equipment Overview
The number of hybrid and battery-electric vehicles coming into workshops for maintenance or repair is continuously increasing. To utilize this service potential, Bosch offers a range of specialized test equipment for diagnosis and repair of high-voltage battery modules.
Bosch stands by workshops as a strong partner, aiming to satisfy customer needs and increase profitability. This includes high-quality products, reliable services, and efficient diagnostic equipment.
Demand-oriented Bosch test equipment
The user-friendly battery tightness tester BTD 101 tests the low- and high-pressure leakage of a wide variety of modules, such as battery packs, liquid cooling plates, and motor-driven enclosures. The battery charger/discharger BAL 2260 diagnoses the state of charge (SOC) of high-voltage batteries, charging or discharging them, and improving maintenance efficiency. The modern battery cell balancer BCB 5524 balances the voltage of high-voltage battery cells, improving their performance.
Technical support
When servicing and repairing electric vehicles, even experienced technicians sometimes encounter problems that are difficult to solve. Highly qualified experts of the technical hotline support team, with their excellent technical workshop expertise, ensure quick problem resolution and simplify everyday work.
Battery charger/discharger BAL 2260
Image description: A Bosch BAL 2260 device is shown, featuring a large touchscreen interface, prominent red emergency stop button, green rotary switches for battery connection, and AC power input. The screen displays icons for device initialization, software upgrading, discharging, reporting, language settings, and general settings.
Product details
The Bosch BAL 2260 charger/discharger diagnoses the state of charge (SOC) at module level and balances it individually. It is primarily used for the rapid charging and discharging of offline battery pack modules in electric vehicles, enhancing maintenance efficiency.
Advantages at a glance
- [check] Fast status check of cell and wire connection through immediate voltage detection.
- [check] Reduction of maintenance time thanks to rapid charging and discharging with high voltage.
- [check] Comprehensive monitoring through real-time control of voltage, current, and temperature for battery health and wiring integrity.
- [check] Quick initialization thanks to pre-installed software and guided start-up.
- [check] Immediate power cut-off via emergency stop button ? to protect both users and equipment in critical situations.
Technical data
| Parameter | Value |
|---|---|
| Power input | AC 90–264 V/40–60 Hz 16 A |
| Display | 10" LCD touchscreen |
| Embedded storage | 32 GB |
| Dis/charging power | Max. 7 kW/3.5 kW |
| Dis/charge voltage | DC 2–260 V |
| Dis/charge current | 0–60 A |
| Single battery cell voltage collect channel | 24 channels |
| Current battery support | LFP, NCM, LTO, LMO, NiMH |
| Current control accuracy | ±0.5% FS |
| Voltage control accuracy | ±0.1% FS |
| Weight | Approx. 27 kg |
Battery cell balancer BCB 5524
Image description: A Bosch BCB 5524 device is shown, similar in design to the BAL 2260 but slightly smaller, featuring a touchscreen, emergency stop button, and connection terminals. The screen displays icons for initialization, language settings, balancing, recording, and instructions.
Product details
The modern Bosch BCB 5524 precisely balances the voltage of HV battery cells. In this way, it improves the performance and extends the service life of battery packs in electric vehicles.
Advantages at a glance
- [check] Fast status check of cell and wire connection through immediate voltage detection.
- [check] Precise and efficient voltage balancing through independent management of each cell's balance.
- [check] High performance and early identification of operational failures by continuous control of battery voltage, current, and temperature.
- [check] Quick initialization thanks to pre-installed software and guided start-up.
- [check] Immediate power cut-off via emergency stop button ? to protect both users and equipment in critical situations.
Technical data
| Parameter | Value |
|---|---|
| Power input | AC 90–264 V/40–60 Hz 10 A |
| Display | 10" LCD touchscreen |
| Embedded storage | 32 GB |
| Dis/charging power | Max. 600 W |
| Dis/charge voltage | DC 1–5 V |
| Dis/charge current | 0.1–5 A |
| Discharging/charging mode | CC-CV |
| Current control accuracy | ±50 mA |
| Voltage control accuracy | ±5 mV |
| Weight | 17 kg |
Battery tightness tester BTD 101
Image description: A Bosch BTD 101 device is shown, a compact, rugged unit with a green casing, touchscreen display, and various connectors and ports. It features a prominent red emergency stop button and a green start button. The screen displays icons for Home, Vehicle, Test, Record, Update, and Settings.
Product details
The user-friendly low- and high-pressure tightness tester BTD 101 is for a wide range of modules such as battery packs, liquid cooling plates, and motor-driven boxes. It operates with automatic pressure regulation and comprehensive data management.
Advantages at a glance
- [check] Quick and secure test head attachment prevents device damage caused by accidental disconnections.
- [check] Precise pressure adjustments for reliable and consistent test results thanks to automatic pressure regulation by servo motor control.
- [check] Suitable for various components like battery packs and motor drive boxes by supporting low- and high-pressure tests.
- [check] Quick initialization thanks to pre-installed software and guided start-up.
- [check] Convenient online updates and no need for a PC through automatic checks and software updates via WiFi ?.
- [check] Comprehensive logging and reporting with support of troubleshooting and customer documentation by operational data logs and detailed test reports.
Technology
The BTD 101 tightness tester is an essential tool for workshops involved in maintaining or optimizing battery packs of electric vehicles.
Diagram description: The BTD 101 device is shown with numbered callouts pointing to its features:
- 1: Air outlet
- 2: Air intake (for 0.4 – 0.8 MPa gas source)
- 3: USB port [USB] (for memory stick)
- 4: WiFi stick or barcode scanner
- 5: Alternative port (Micro USB)
- 6: Power adapter 24 V/DC
Enhanced diagnostic accuracy
The BTD 101 provides precise and reliable airtightness testing for critical components like battery packs and cooling systems, helping to detect even the smallest leaks. The high level of accuracy ensures thorough and effective repairs, boosting the safety and performance of the serviced vehicles.
Improving efficiency and productivity
Automatic pressure regulation and user-friendly interface streamline the testing process. The BTD 101 quickly adjusts to the required pressure settings and performs tests with minimal manual intervention, allowing technicians to focus on other tasks and save time.
Up-to-date with technology
The online update capability via a USB-WiFi stick ensures the equipment always runs the latest software.
Comprehensive data management
Easy storage, management, and export of test results with the BTD 101's robust data handling features.
Future-proof operations
As the automotive industry evolves towards more advanced and eco-friendly technologies, the BTD 101 equips the workshop to handle the latest in electric vehicles.
Technical data
| Parameter | Value |
|---|---|
| Pressure range |
|
| Automatic pressure regulation range | 0–500 kPa |
| Range of testing time | 0–9999 s |
| Detection standard display resolution | 0.1 Pa |
| Display | 10" LCD touchscreen |
| Operating system | Android 4.4.2 |
| Processor | ARM Cortex-A9 Tetranuclear S5P 4418 1.4 GHz |
| Random access memory | 1 GB DDR3 |
| Hard disk space | 16 GB EMMC |
| Language | English |
| Ingress protection standard | IP41 |
| Certification information | CE, RoHS |
| Power adapter | AC 110–240 V, 50–60 Hz |
| Operating temperature range | 0–50°C |
| Humidity requirements for operation | 10–90% (+25°C) |
| Air pressure requirements for operation environment | 80–108 kPa |
| Dimensions (L x W x H) | 413 x 238 x 253 mm |
| Weight | 5.3 kg |
Accessories and trainings
Image description: Two sets of accessories are shown. The first set, associated with the BAL 2260, includes various cables, power cords, and a USB memory stick. The second set, for the BCB 5524, includes similar cables and a USB memory stick.
The BAL 2260 HV charger/discharger comes with a range of accessories (excerpt): power cords, charging/discharging cables, voltage and temperature measuring box and cables, USB memory stick, WLAN adapter.
The BCB 5524 HV cell balancer comes with a range of accessories (excerpt): power cords, voltage and temperature measuring cables, USB memory stick.
Bosch – know-how, test equipment and service training from a single source
Bosch workshop support on high-voltage systems
As a developer of innovative solutions and supplier of hybrid and electric drive technology for original equipment, Bosch is shaping technological change in the vehicle and workshop market. Bosch offers extensive workshop equipment and technical support in the aftermarket.
Fit for high-voltage with Bosch service trainings
For jobs on electric and hybrid vehicles, such as high-voltage battery repairs, extensive knowledge of complex high-voltage technology is necessary. Bosch therefore offers a range of service trainings and legally required qualification measures for workshops.
High voltage repair kit
In case the HV battery is defective or aged, replacement is not the only possible solution. For Toyota Prius III, Yaris or Lexus CT 200h with aged HV modules, Bosch offers a repair-kit with new long-life Bosch nickel metal hydride modules – cost-effective and saving valuable resources.
Service information
The BCB 5524 battery cell balancer, the BAL 2260 battery charger/discharger, and the BTD 101 battery tightness tester may only be used with the appropriate HV qualification. Bosch offers specified trainings.
Find out more about Bosch service trainings by scanning the QR code! ? (QR code present for more information)
What drives you, drives us
Bosch technologies are used in most vehicles worldwide. People, and assuring their mobility, is what we are focused on. Therefore, Bosch has dedicated over 130 years of pioneering spirit and expertise in research and manufacturing to achieving this.
Bosch provides the aftermarket and workshops worldwide with modern diagnostic and workshop equipment and a wide range of spare parts for passenger cars and commercial vehicles:
- Solutions for efficient vehicle repairs.
- Innovative workshop equipment and software.
- One of the world's most comprehensive ranges of new and exchange parts.
- Large network of wholesale customers for quick and reliable parts supply.
- Competent hotline support.
- Comprehensive educational and training offers.
- Targeted sales and marketing support.
Find out more at: boschaftermarket.com
Robert Bosch GmbH
Auf der Breit 4
76227 Karlsruhe
Germany
2025/09 Subject to technical and program changes.
