MaxiEV ALT100L - Battery tester Autel - Free user manual and instructions

Product Type	Battery Leakage Tester
Model	MaxiEV ALT100L
Dimensions (W x L x H)	280 x 300 x 200 mm
Weight	3.5 kg
Power Supply	AC 90-265V, 50/60Hz, 20W max
Test Method	Pressure decay (nondestructive)
Test Pressure Range	0-30 kPa
Sensor Resolution	1 Pa
Test Accuracy	±5 Pa
Display	7-inch LCD touch screen
Communication Ports	RS485, USB 2.0
Data Storage	Internal memory and export via USB
Air Supply	0.1-1.0 MPa dry compressed air
Air Inlet / Outlet Ports	φ6 mm air pipes
Operating Temperature	-5°C to 50°C
Storage Temperature	-20°C to 70°C
Operating Humidity	10% to 90% RH @25°C (non-condensing)
Components Included	Main unit, air inlet pipe, air outlet pipe, AC power cord, USB disk, user manual, carrying case
Key Features	High sensitivity sensor, large screen, barcode scanner support, visualized test process, pressure dual display, parameter memory, intelligent alarm, remote management (optional)
Safety Features	Audible and visual alarms for abnormal conditions; power switch; grounded power requirement
Warranty	1 year for main unit (excluding artificial damage)
Application	Leakage test of EV battery packs
Calibration	Supported via settings menu
Language Support	English, Simplified Chinese, Traditional Chinese

Frequently Asked Questions - MaxiEV ALT100L Autel

What is the Autel MaxiEV ALT100L used for?

The Autel MaxiEV ALT100L is a battery leakage tester designed for nondestructive leak testing of electric vehicle (EV) battery packs. It uses compressed air to apply pressure and detects pressure changes to identify leaks.

How do I connect the air supply and battery pack?

Connect a 6mm air pipe from the dry compressed air source (0.1-1.0 MPa) to the Air Inlet Port on the back panel. Then connect another 6mm pipe from the Low Pressure (LP) Air Outlet Port to the battery pack. Ensure all connections are airtight.

What power supply does the device require?

The device operates on AC 90-265V, single-phase three-wire (with ground). It draws a maximum of 20W. Always ensure the power outlet is properly grounded and turn off the power switch before connecting.

Can I use the tester in rainy or humid conditions?

No. The operating humidity is 10-90% RH at 25°C (non-condensing). Outdoor use in rainy weather is prohibited. Avoid corrosive or explosive environments.

How do I start a leakage test?

After connecting the device and turning on power, the main menu appears. Tap Low Pressure Mode, then press the Set icon to configure parameters (pack ID, target pressure, times, etc.). Press Save, then press Start. The test runs through Preparation, Inflation, Holding, Test, and Deflation stages.

What does the test result 'Unqualified' mean?

If at any stage the actual pressure or leakage exceeds the preset limits, the system displays 'Unqualified'. The device will alert with audible and visual alarms. Follow the on-screen notes to adjust parameters or check connections.

How can I export test data?

Insert a USB disk into the USB port on the front panel. From the Data Management page, select the test records you wish to export (or select all) and press Export. The data (including test process screenshots) will be copied to the USB disk.

How do I perform a system update or calibration?

Go to Settings > Device Maintenance for local updates (contact manufacturer for update files). For online upgrades, connect to Wi-Fi via Settings > Wi-Fi Connection. Calibration is available under Settings > Calibration – follow manufacturer guidance.

What maintenance does the tester require?

Regularly clean the mesh cover of the heat outlet to remove dust. For long-term storage, keep in a dry place (-20°C to 70°C, humidity <90%). The warranty covers one year from receipt; free repair during defects liability period. Do not disassemble without permission.

Can I use the tester with different battery sizes?

Yes. In the Parameter Settings, you can set the Pack Volume (L), Target Pressure, and times (inflation, holding, test, deflation) according to your battery pack. The system remembers the last parameters for convenience.

USER MANUAL MaxiEV ALT100L Autel

2. Safety Precautions....3

2.1 Operator Requirements .... 3
2.2 Operating Environment....3
2.3 Connection Precaution....3
2.4 Operating Precautions 4
2.5 Common Misoperation....4
2.6 Emergency Treatments on Abnormal Conditions 4
2.7 Other Safety Warnings....4

3. Main Technical Parameters ....5

4. Installation 5

5. Device Connection....6

5.1 Panel Description....6
5.2 Device Connection ....7
5.2.1 Air Supply Connection....7
5.2.2 Battery Pack Connection....7
5.2.3 AC Input Connection....7

6. Operating Instruction 8

6.1 Starting Up....8
6.2 Settings....8
6.2.1 Language....9
6.2.2 Units 9
6.2.3 Wi-Fi Connection....9
6.2.4 Log Management 9
6.2.5 Device Maintenance ....10
6.2.6 About....10
6.2.7 Calibration 10
6.2.8 Parameter Settings 10

6.3 Low Pressure Mode Leakage Test....11

6.3.1 Parameters Setting ......12
6.3.2 Test Start....13

6.4 Data Management....13

1. Repair & Maintenance....15
2. Transportation & Storage 15
3. Environmental Statement....15

1. Overview

MaxiEV ALT100L Battery Leakage Tester is a newly developed high-accuracy nondestructive testing equipment. It mainly uses compressed air as the medium to apply specific pressure to the inner cavity or surface of the battery to be tested and then uses sensitive sensors to detect the variations of pressure to determine the leakage of the battery pack. It can improve customer testing efficiency and product quality with pollution-free, quick, and accurate testing characteristics in the new energy industry.

1.1 Features

• High Sensitivity: High-sensitivity pressure sensing significantly improves test accuracy and stability.
• Large Screen Display: A 7-inch big-size LCD touch screen visually displays the test progress and data.
• Barcode Scanner: it supports barcode scanner access, directly scans code, and displays the battery pack's ID to be tested.
• Visualized Process: display the progress time of each stage during the test.
• Pressure Dual Display: the pressure dial and the test curve will display on the same screen in real time.
• Parameters Management: the system auto-remembers the last test parameters, which is convenient for the next test modification and improves efficiency.
• Intelligent Alarm: the tester will prompt audible and visual alarms to ensure safety when the test is abnormal or failed.

- Remote Management: the device supports online system upgrades, and the optional cloud platform can realize remote data transmission and management.

1.2 Applications

This equipment is mainly used for the leakage test of battery packs.

1.3 Device Component

It is configured with the main unit, air inlet pipe, air outlet pipe, AC power cord, USB disk, user manual, and carrying case.

The main unit is organized by color LCD touch screen, data processing unit, and data acquisition unit.

graph TD
    A["MaxiEV ALT100L"] --> B["Main Unit*1"]
    A --> C["Air Inlet Pipe*1"]
    A --> D["Air Outlet Pipe*1"]
    A --> E["AC Power Cord*1"]
    A --> F["USB Disk*1"]
    A --> G["User Manual*1"]
    A --> H["Carrying Case*1"]
    B --> I["LCD Touch Screen"]
    C --> J["Data Processing Unit"]
    D --> K["Data Acquisition Unit"]

2. Safety Precautions

2.1 Operator Requirements

Alarm

1) Operators are required to receive training related to the use of the equipment before operating.
2) Before operating, operators should read the user manual and the related regulations.
3) Please do not disassemble without the manufacturer's permission.

2.2 Operating Environment

Alarm

1) Operating temperature: -5\~50°C.
2) Relative humidity: 10\~90% @25°C, rainy day outdoor use is prohibited.
3) Non-corrosive, explosive, and destructive insulation gases and conductive dust of the test environment are required.

2.3 Connection Precaution

Alarm

1) Ensure the unit's AC power switch is off before completing all connecting.
2) Please strictly follow the instructions to connect the cables properly.

Danger

Warning signs need to be placed in the test work area to avoid the risk of tripping over the cable.

Alarm

When the equipment is running, it is necessary to ensure that the air inlet and outlet are free of obstructions.

2.4 Operating Precautions

The operation of the device is by touching the screen input. Please follow the screen prompts.

Alarm

The working power of this device is AC90\~265V. Please make sure the operating power is reliably grounded.

Alarm

Do not let the tester run unattended.

2.5 Common Misoperation

1) Operating tools are not insulated.
2) Operating the device without following the user manual.

2.6 Emergency Treatments on Abnormal Conditions

Disconnect the power supply.

2.7 Other Safety Warnings

Strictly observe safe operating practices and correct operation methods.

1. Main Technical Parameters

Model	MaxiEV ALT100L
Applicable	Suitable for the leakage test of EV battery packs
Test Power	20W max
Test Method	pressure
Test Pressure Range	0-30Kpa
Sensor Resolution	1Pa
Test Accuracy	±5Pa
Display	7-inch LCD touchscreen
Communication Port	RS485, USB
Data Storage	Internal memory/download via USB disk
Power Supply	AC90~265V
Air Supply	0.1~1.0 Mpa dry compressed air
Air Inlet Port	φ6mm air pipe
Test Port	φ6mm air pipe
Work Temperature	-5~50°C
Storage Temperature	-20~70°C
Work Humidity	10%~90% @25°C, without condensation
Dimension(mm)	280*300*200(W*L*H)
Weight	3.5kg
Optional	air converter

4. Installation

This device is mobile portable equipment and does not involve installation.

5. Device Connection

5.1 Panel Description

Front View

Back View

No.	Name	Description
1	USB Port	for test data export and system local update
2	RS485 Port	for data copy and transmit
3	AC Power Supply	AC90~265V input and power switch
1	Air Inlet Port	air supply inlet
5	LP Air Outlet Port	low-pressure output
6	HP Air Outlet Port	not currently supported

5.2 Device Connection

Please connect as per the instruction, and check all connections are fastened after joining.

5.2.1 Air Supply Connection

Connect the air source and tester's Air Inlet Port with a 6mm air pipe.

5.2.2 Battery Pack Connection

Connect the battery pack and tester's Air Outlet Port with a 6mm air pipe. Please ensure the airtightness of the connection.

5.2.3 AC Input Connection

Connect the power supply and the tester. The working power input is a single-phase three-wire AC220V.

6. Operating Instruction

6.1 Starting Up

After the device connection, turn on the AC Power Switch to start the tester.

The screen will display the Boot Animation with the Welcome and AUTEL brand logo, and then the system will automatically jump to the Main Menu Page, including Low Pressure Mode, Data Management, and Settings functions.

Boot Animation

MaxiEV ALT100L Battery Leakage Tester

Low Pressure Mode

Data Management

Settings

Main Menu Page

6.2 Settings

Press the Settings icon on the Main Menu Page to enter the Settings Page. It has eight sub-pages: Language, Units, Wi-Fi Connection, Log Management, Device Maintenance, About, Calibration, and Parameter Settings.

6.2.1 Language

The system supports three language switching, including English, Simplified Chinese, and Traditional Chinese.

Settings > Language

Settings > Unit

6.2.2 Units

Set the leakage unit according to the actual testing requirements.

6.2.3 Wi-Fi Connection

A wireless network connection is for online system upgrades of the standard unit and data transmission of optional cloud platform functions.

Settings > Wi-Fi Connection

Settings > Log Management

6.2.4 Log Management

The running log is used for analysis by manufacturers when analyzing exceptions. There is no need for the user to operate. Contact the manufacturer for guidance when the device is abnormal.

6.2.5 Device Maintenance

It is for local updates, module update, and date & time calibration. If necessary, please contact the manufacturer to get the updated file and operate following the manufacturer's guidance.

Settings > Device Maintenance

Settings > About

6.2.6 About

It will show the device info about the current software version, device ID, and device model, and users can operate the online upgrade on the page.

6.2.7 Calibration

It is used for calibration. Please operate according to actual test requirements.

Settings > Calibration

Settings > Parameter Settings

6.2.8 Parameter Settings

There are two inflation modes, including Default (2s) and Straight. Please select the proper inflation mode according to the actual testing situation, and press

Save to save the setting.

Default (2s): The inflation valve closes every 2 seconds, and the system detects the inner pressure after every 2 seconds.

Straight: The inflation is completed at one time, and the inflation valve will not be closed during the inflating process.

6.3 Low Pressure Mode Leakage Test

Low Pressure Test Page

Press Low Pressure Mode on the Main Menu Page to enter the Low Pressure Test Page. There are four parts on the page:

1 Real-time Data: display the real-time pressure value of the tested battery pack.
2 Leakage: display the real-time leakage value of the tested battery pack.
3 Test Info:

● show the battery pack ID and target pressure;
● show the test status and the test result;
- Set function icon for setting test parameters;
- Start and Stop function icons for test control.

1 Test Process: display the whole test progress as a curve.

6.3.1 Parameters Setting

Press the Set icon to set the test parameters. Users need to confirm the test parameters before testing. Remember to press Save to take effect.

For the first test, users need to complete the setting of all parameters. The system will automatically save the last test parameter, and you can enter the

Parameters Setting Page to confirm or modify it when you start the test next time.

Parameters Setting Page

Parameter	Description
Pack ID:	Name the battery pack, and you can input the actual ID.
Pack Volume (L):	The battery pack volume; fill in the actual pack volume.
Target Pressure (kPa):	Set the target pressure for inflation.
Max Pressure (kPa):	The upper limit of the test range. It will be displayed on the real-time pressure dial.
Min Pressure (kPa):	The lower limit of the test range. It will be displayed on the real-time pressure dial.
Leakage (Pa):	Airtightness determines condition. actual leakage value ≤ Leakage → Qualified actual leakage value > Leakage → Unqualified
Inflation Time (s):	The inflation time can be set according to the battery pack size.
Holding Time (s):	A holding time that the tester will stop inflating and wait for inner pressure change.
Test Time (s):	The test time that the tester detects pressure changes after the Holding Time. The test page will display the test result after detection.
Deflation Time (s):	The time to deflate air after the test is complete.

6.3.2 Test Start

Confirm the test parameters and press Save to back to the Low Pressure Test Page, then press Start to start the test. Users can check the real-time test data on the page. The test process will be carried out in the order of preparation (10s), Inflation, Holding, Test, and Deflation.

Test Start

Unqualified Test Result

No matter in which test stage, as long as the actual test data does not meet the preset parameters, the system will determine the test result as Unqualified. Please operate following the system Note.

6.4 Data Management

Press the Data Management icon on the Main Menu Page. The system supports automatic data saving during all testing processes and can view, delete, and export data on the Data Page after testing.

1) View

Slide the page to browse all test data. Click on the test data you want to check, and the system will show the test process screenshot to show you

the details.

2) Delete

Check or select all test data and press Delete to confirm the deletion.

3) Export

Insert the USB disk into the device's USB port, check or select all saved data, and press Export to download the corresponding data to the USB disk.

Data Page

7. Repair & Maintenance

1) The warranty period of the main tester is one year from the date of receipt, and the warranty does not cover artificial damage.
2) The manufacturer provides free repair during the defects liability period and technical consulting services for a lifetime. If you have any technical problems or advice, please get in touch with the manufacturer.
3) When the equipment is stored for a long time, there may be dust and other dirt on the mesh cover of the heat outlet, which needs to be cleaned regularly.

8. Transportation & Storage

1) This tester is equipped with a particular carry case and transported in a carton, which is shock-resistant and reliable in transportation.
2) Storage conditions: placed in a dry equipment storage room, temperature: -20\~70°C, humidity: <90%.

9. Environmental Statement

1) The tester uses a transport carton which is a recyclable material.
2) The main machine and other components are non-polluting sources.